Rotary powered articulation joints for surgical instruments

ABSTRACT

An articulation joint for a surgical instrument. In at least one form, the articulation joint includes a proximal joint portion that is coupled to an elongate shaft assembly of the surgical instrument. A distal joint portion is movably coupled to the proximal joint portion and is configured to interface with a surgical end effector. A first gear train operably interfaces with a proximal firing shaft segment within the elongate shaft assembly and a distal firing shaft segment that is configured to operably interface with the surgical end effector for transmitting a rotary firing motion thereto from the proximal firing shaft segment to the surgical end effector. A second gear train operably interfaces with a proximal rotation shaft portion of the elongate shaft assembly for transmitting a distal rotational control motion to the surgical end effector to cause the surgical end effector to rotate relative to the elongate shaft assembly while facilitating articulation of the distal joint portion relative to the proximal joint portion.

FIELD OF THE INVENTION

The present invention relates to surgical instruments and, in variousarrangements, to surgical cutting and stapling instruments and staplecartridges therefor that are designed to cut and staple tissue.

BACKGROUND

Surgical staplers are often used to deploy staples into soft tissue toreduce or eliminate bleeding from the soft tissue, especially as thetissue is being transected, for example. Surgical staplers, such as anendocutter, for example, can comprise an end effector which can bemoved, or articulated, with respect to an elongate shaft assembly. Endeffectors are often configured to secure soft tissue between first andsecond jaw members where the first jaw member often includes a staplecartridge which is configured to removably store staples therein and thesecond jaw member often includes an anvil. Such surgical staplers caninclude a closing system for pivoting the anvil relative to the staplecartridge.

Surgical staplers, as outlined above, can be configured to pivot theanvil of the end effector relative to the staple cartridge in order tocapture soft tissue therebetween. In various circumstances, the anvilcan be configured to apply a clamping force to the soft tissue in orderto hold the soft tissue tightly between the anvil and the staplecartridge. If a surgeon is unsatisfied with the position of the endeffector, however, the surgeon must typically activate a releasemechanism on the surgical stapler to pivot the anvil into an openposition and then reposition the end effector. Thereafter, staples aretypically deployed from the staple cartridge by a driver which traversesa channel in the staple cartridge and causes the staples to be deformedagainst the anvil and secure layers of the soft tissue together. Often,as known in the art, the staples are deployed in several staple lines,or rows, in order to more reliably secure the layers of tissue together.The end effector may also include a cutting member, such as a knife, forexample, which is advanced between two rows of the staples to resect thesoft tissue after the layers of the soft tissue have been stapledtogether.

Such surgical staplers and effectors may be sized and configured to beinserted into a body cavity through a trocar or other access opening.The end effector is typically coupled to an elongate shaft that is sizedto pass through the trocar or opening. The elongate shaft assembly isoften operably coupled to a handle that supports control systems and/ortriggers for controlling the operation of the end effector. Tofacilitate proper location and orientation of the end effector withinthe body, many surgical instruments are configured to facilitatearticulation of the end effector relative to a portion of the elongateshaft.

The foregoing discussion is intended only to illustrate various aspectsof the related art in the field of the invention at the time, and shouldnot be taken as a disavowal of claim scope.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of this invention, and the manner ofattaining them, will become more apparent and the invention itself willbe better understood by reference to the following description ofembodiments of the invention taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a perspective view of a surgical stapling instrument of oneform of the present invention;

FIG. 2 is another perspective view of the surgical instrument of FIG. 1with a portion of the handle housing removed;

FIG. 3 is an exploded assembly view of one effector arrangement of thepresent invention

FIG. 4 is a partial cross-sectional view of a portion of the endeffector and the elongate shaft assembly of the surgical instrument ofFIGS. 1 and 2 with the anvil assembly in an open position;

FIG. 5 is another partial cross-sectional view of the end effector andelongate shaft assembly of FIG. 4 with the anvil assembly in a closedposition prior to firing;

FIG. 6 is another partial cross-sectional view of the end effector andelongate shaft assembly of FIGS. 4 and 5 after the tissue cutting memberhas been advanced to a distal-most position within the end effector;

FIG. 7 is a perspective view of a coupler assembly arrangement of thepresent invention;

FIG. 8 is an exploded assembly view of the coupler assembly of FIG. 7;

FIG. 9 is a perspective view of the proximal end of the end effector andthe distal end of the elongate shaft assembly and coupler assemblyattached thereto;

FIG. 10 is an elevational view of the proximal end of the end effectorof FIG. 9;

FIG. 11 is an elevational view of the distal end of the coupler assemblyof FIG. 9;

FIG. 12 is a perspective assembly view of a portion of the end effectorand elongate shaft assembly prior to coupling the end effector thereto;

FIG. 13 is another perspective view of a portion of an end effector andelongate shaft assembly arrangement after the end effector has beeninitially engaged with a coupler assembly portion of the elongate shaftassembly;

FIG. 14 is another perspective view of the components depicted in FIG.13 after the end effector has been coupled to the coupler assemblyportion of the elongate shaft assembly;

FIG. 15 is a perspective view of an articulation control arrangement ofthe present invention;

FIG. 16 is a perspective view of a portion of an articulation shaftsegment arrangement;

FIG. 17 is an exploded perspective view of an articulation jointarrangement of the present invention;

FIG. 18 is a perspective view of the articulation joint arrangement ofFIG. 17;

FIG. 19 is a top view of the articulation joint arrangement of FIGS. 17and 18;

FIG. 20 is a cross-sectional view of the components illustrated in FIG.19;

FIG. 21 is another cross-sectional view of the articulation joint ofFIGS. 19 and 20;

FIG. 22 is another cross-sectional view of the articulation joint ofFIG. 21 in an articulated configuration;

FIG. 23 is a perspective view of a firing system arrangement of thepresent invention;

FIG. 24 is a perspective view of an end effector rotation systemarrangement of the present invention;

FIG. 25 is a perspective view of a portion of an articulation joint andcoupler assembly of the present invention;

FIG. 26 is a perspective view of a shaft rotation system arrangement ofthe present invention;

FIG. 27 is an exploded perspective view of the surgical instrument ofFIGS. 1 and 2;

FIG. 28 is an exploded perspective view of a detachable drive mountarrangement of the present invention;

FIG. 28A is an end elevational view of a portion of the detachable drivemount arrangement of FIG. 28 attached to a motor mounting assemblyarrangement;

FIG. 28B is a perspective view of a portion of the detachable drivemount arrangement and motor mounting assembly arrangement of FIG. 28A;

FIG. 29 is a cross-sectional view of a portion of a handle assemblyarrangement;

FIG. 30 is an exploded assembly view of a detachable drive mount andmotor mounting assembly within the handle housing portions;

FIG. 31 is an exploded assembly view of a motor mounting assemblyarrangement;

FIG. 32 is another an exploded cross-sectional assembly view of thedetachable drive mount and motor mounting assembly within the handlehousing portions;

FIG. 33 is a side elevational view of a portion of the handle assemblywith various components omitted for clarity;

FIG. 34 is a bottom perspective view of a switch arrangement of thepresent invention;

FIG. 35 is an exploded assembly view of the switch arrangement of FIG.34;

FIG. 36 is a cross-sectional view of portion of the switch arrangementof FIGS. 34 and 35 mounted with the handle assembly wherein the joystick control portion is in an unactuated position;

FIG. 37 is another cross-sectional view of the switch arrangement ofFIG. 36 with the joy stick control portion in an actuated position;

FIG. 38 is a side cross-sectional view of the switch arrangement of FIG.36;

FIG. 39 is a side cross-sectional view of the switch arrangement of FIG.37;

FIG. 40 is a side elevational view of the switch arrangement of FIGS.34-39;

FIG. 41 is a front elevational view of the switch arrangement of FIGS.34-40;

FIG. 42 is another exploded assembly view of the switch arrangement ofFIGS. 34-41;

FIG. 43 is a rear elevational view of a thumbwheel paddle controlassembly arrangement in an actuated position;

FIG. 44 is another rear elevational view of the thumbwheel paddlecontrol assembly arrangement in another actuated position;

FIG. 45 is another partial cross-sectional view of an end effector andelongate shaft assembly arrangement;

FIG. 46 is an enlarged cross-sectional view of a portion of anarticulation joint arrangement and coupler assembly arrangement with anend effector coupled thereto;

FIG. 47 is a perspective view of a portion of the handle assemblyarrangement with a portion of the handle housing removed;

FIG. 48 is an enlarged perspective view of a portion of a handleassembly illustrating a conductor coupling arrangement;

FIG. 49 is an exploded perspective view of a portion of another couplerassembly arrangement and articulation joint arrangement;

FIG. 50 is a perspective view of another articulation joint arrangementof the present invention;

FIG. 51 is an exploded assembly view of the articulation jointarrangement of FIG. 50;

FIG. 52 is a cross-sectional view of the articulation joint arrangementof FIGS. 50 and 51;

FIG. 53 is another cross-sectional perspective view of the articulationjoint arrangement of FIGS. 50-52;

FIG. 54 is a perspective view of another articulation joint arrangementof the present invention;

FIG. 55 is an exploded assembly view of the articulation jointarrangement of FIG. 54;

FIG. 56 is a partial cross-sectional view of the articulation jointarrangement of FIGS. 54 and 55;

FIG. 57 is another partial cross-sectional view of the articulationjoint arrangement of FIGS. 54-56;

FIG. 58 is another partial perspective cross-sectional view of thearticulation joint arrangement of FIGS. 54-57;

FIG. 59 is another partial perspective cross-sectional view of thearticulation joint arrangement of FIGS. 54-58 with the joint in anarticulated orientation;

FIG. 60 is another partial perspective cross-sectional view of thearticulation joint arrangement of FIGS. 54-59 with the joint in anotherarticulated orientation;

FIG. 61 is a perspective view of another articulation joint arrangementof the present invention;

FIG. 62 is another perspective view of the articulation jointarrangement of FIG. 60 in an articulated orientation;

FIG. 63 is an exploded assembly view of the articulation joint of FIGS.61 and 62;

FIG. 64 is a cross-sectional view of the articulation joint arrangementof FIGS. 61-63;

FIG. 65 is another cross-sectional perspective view of the articulationjoint arrangement of FIGS. 61-64;

FIG. 66 is another cross-sectional perspective view of the articulationjoint arrangement of FIGS. 61-65 with the articulation joint in anarticulated orientation;

FIG. 67 is a perspective view of another motor mounting assemblyarrangement of the present invention;

FIG. 68 is a front elevational view of the motor mounting assemblyarrangement of FIG. 67;

FIG. 69 is an exploded assembly view of the motor mounting assemblyarrangement of FIGS. 67 and 68;

FIG. 70 shows a perspective view of some forms of an electrosurgical endeffector for use with the surgical instrument;

FIG. 71 shows a perspective view of some forms of the end effector ofFIG. 70 with the jaws closed and the distal end of an axially movablemember in a partially advanced position;

FIG. 72 is a perspective view of some forms of the axially moveablemember of the end effector of FIG. 70;

FIG. 73 is a section view of some forms of the end effector of FIG. 70;

FIG. 74-75 illustrates one form of an ultrasonic end effector for usewith the surgical instrument;

FIGS. 76-77 show additional views of one form of the axially movablemember of the end effector of FIG. 74;

FIG. 78 illustrates one form of a linear staple end effector that may beused with the surgical instrument;

FIG. 79 illustrates one form of a circular staple end effector that maybe used with the surgical instrument;

FIG. 80 illustrates several example power cords for use with thesurgical instrument;

FIG. 81 illustrates several example shafts that can be used with thesurgical instrument;

FIG. 82 is a block diagram of the handle assembly of the surgicalinstrument showing various control elements;

FIG. 83 illustrates one form of various end effector implement portionscomprising circuits as described herein;

FIG. 84 is a block diagram showing one form of a control configurationto be implemented by the control circuit to control the surgicalinstrument;

FIG. 85 is a flowchart showing one example form of a process flow forimplementing the control algorithm of FIG. 84;

FIG. 86 is a block diagram showing another form of a controlconfiguration to be implemented by the control circuit to control thesurgical instrument;

FIG. 87 is a flowchart showing one example form of a process flow forimplementing the control algorithm of FIG. 86;

FIG. 88 illustrates one form of a surgical instrument comprising a relaystation in the handle;

FIG. 89 illustrates one form of an end effector with a sensor moduleconfigured to transmit a signal disposed therein;

FIG. 90 is a block diagram showing one form of a sensor module;

FIG. 91 is a block diagram showing one form of a relay station;

FIG. 92 is a block diagram showing one form of a relay stationconfigured to convert a received low-power signal;

FIG. 93 is a flow chart of one form of a method for relaying a signalindicative of a condition at an end effector;

FIG. 94 illustrates a distal portion of an instrument comprising amechanical stop as illustrated in FIG. 1 according to certain aspectsdescribed herein;

FIG. 95 is a diagram of a system adaptable for use with anelectromechanical stop comprising a power source, a control system, anda drive motor according to according to certain aspects describedherein;

FIG. 96 is a graphical illustration depicting change in current overtime associated with an instrument comprising an electromechanical stopwithout a soft stop according to certain aspects described herein;

FIG. 97 illustrates a distal portion of an instrument equipped with amechanical stop comprising a soft stop wherein the drive member isactuated to a position prior to contact with the soft stop at a secondposition of an end of stroke according to certain aspects describedherein;

FIG. 98 illustrates the instrument shown in FIG. 97 wherein the drivemember is actuated through the first position of the end of stroke tothe second position of the end of stroke according to certain aspectsdescribed herein;

FIG. 99 is a graphical illustration depicting change in current overtime associated with an instrument comprising an electromechanical stopwith a soft stop according to certain aspects described herein;

FIG. 100 is a perspective view of an alternative motor mounting assemblythat employs a gear driven drive mount assembly;

FIG. 101 is another perspective view of the motor mounting assembly ofFIG. 100 with the distal shaft housing omitted for clarity;

FIG. 102 is another perspective view of the motor mounting assembly ofFIGS. 100 and 101;

FIG. 103 is a cross-sectional view of the motor mounting assembly ofFIGS. 100-102; and

FIG. 104 is a top view of the motor mounting assembly of FIGS. 100-103.

FIG. 105 illustrates one form of a surgical instrument comprising asensor-straightened end effector in an articulated state.

FIG. 106 illustrates the surgical instrument of FIG. 105 in astraightened state.

FIG. 107 illustrates one form of a sensor-straightened end effectorinserted into a surgical overtube.

FIG. 108 illustrates one form of a sensor-straightened end effectorinserted into a surgical overtube in an articulated state.

FIG. 109 illustrates one form of a sensor-straightened end effector inan articulated state.

FIG. 110 illustrates one form of the sensor-straightened end effector ofFIG. 109 in a straightened state.

FIG. 111 illustrates one form of a magnetic ring for use with asensor-straightened end effector.

FIG. 112 illustrates one form of a sensor-straightened end effectorcomprising a magnetic sensor.

FIG. 113 illustrates one form of a magnetic reed sensor.

FIG. 114 illustrates one form of a modular motor control platform.

FIG. 115 illustrates one form of a modular motor control platformcomprising multiple motor-controller pairs.

FIG. 116 illustrates one form of a modular motor control platformcomprising a master controller and a slave controller.

FIG. 117 illustrates one form of a control process implementable by amultiple-motor controlled surgical instrument.

DETAILED DESCRIPTION

Applicant of the present application also owns the following patentapplications that were filed on even date herewith and which are eachherein incorporated by reference in their respective entireties:

U.S. patent application entitled “Rotary Powered Surgical InstrumentsWith Multiple Degrees of Freedom”, Attorney Docket No.END7195USNP/120287;

U.S. patent application entitled “Articulatable Surgical InstrumentsWith Conductive Pathways For Signal Communication”, Attorney Docket No.END7187USNP/120279;

U.S. patent application entitled “Thumbwheel Switch Arrangements ForSurgical Instruments”, Attorney Docket No. END7189USNP/120281;

U.S. patent application entitled “Joystick Switch Assemblies ForSurgical Instruments”, Attorney Docket No. END7192USNP/120284;

U.S. patent application entitled “Electromechanical Soft Stops ForSurgical Instruments”, Attorney Docket No. END7196USNP/120288;

U.S. patent application entitled “Electromechanical Surgical Device WithSignal Relay Arrangement”, Attorney Docket No. END7190USNP/120282;

U.S. patent application entitled “Sensor Straightened End EffectorDuring removal Through Trocar, Attorney Docket No. END7193USNP/120285;

U.S. patent application entitled “Multiple Processor Motor Control ForModular Surgical Device”, Attorney Docket No. END7091USNP/120283; and

U.S. patent application entitled “Control Methods for SurgicalInstruments with Removable Implement Portions”, Attorney Docket No.END7194USNP/120286.

Certain exemplary embodiments will now be described to provide anoverall understanding of the principles of the structure, function,manufacture, and use of the devices and methods disclosed herein. One ormore examples of these embodiments are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that thedevices and methods specifically described herein and illustrated in theaccompanying drawings are non-limiting exemplary embodiments and thatthe scope of the various embodiments of the present invention is definedsolely by the claims. The features illustrated or described inconnection with one exemplary embodiment may be combined with thefeatures of other embodiments. Such modifications and variations areintended to be included within the scope of the present invention.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” referring to the portion closest to the clinicianand the term “distal” referring to the portion located away from theclinician. It will be further appreciated that, for convenience andclarity, spatial terms such as “vertical”, “horizontal”, “up”, and“down” may be used herein with respect to the drawings. However,surgical instruments are used in many orientations and positions, andthese terms are not intended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, theperson of ordinary skill in the art will readily appreciate that thevarious methods and devices disclosed herein can be used in numeroussurgical procedures and applications including, for example, inconnection with open surgical procedures. As the present DetailedDescription proceeds, those of ordinary skill in the art will furtherappreciate that the various instruments disclosed herein can be insertedinto a body in any way, such as through a natural orifice, through anincision or puncture hole formed in tissue, etc. The working portions orend effector portions of the instruments can be inserted directly into apatient's body or can be inserted through an access device that has aworking channel through which the end effector and elongate shaft of asurgical instrument can be advanced.

Turning to the Drawings wherein like numerals denote like componentsthroughout the several views, FIGS. 1-3 depict a surgical instrument 10that is capable of applying rotary actuation motions to an implementportion 100 operably coupled thereto. As will be discussed in furtherdetail below, the instrument 10 may be effectively employed with avariety of different implements that may be interchangeably coupled tothe instrument 10. The arrangement of FIGS. 1 and 2, for example, isshown coupled to an end effector 102 that is configured to cut andstaple tissue. However, other implement arrangements may also beoperated by the instrument 10.

End Effector

The end effector 102 depicted in FIGS. 1-6 includes an elongate channelmember 110 that may be configured to operably and removably support astaple cartridge 130. The staple cartridge 130 may include an uppersurface or cartridge deck 132 that includes a plurality of staplepockets 134 that are arranged in lines in a staggered fashion on eachside of an elongate slot 136. See FIG. 3. A plurality of surgicalstaples 140 are supported on corresponding staple drivers 138 that areoperably supported within the staple pockets 134. As can also be seen inFIG. 3, in one form, the end effector 102 includes an end base 150 thatis configured to be coupled to a proximal end of the staple cartridge130 and seated within a proximal end of the elongate channel 110. Forexample, the end base 150 may be formed with distally-extending latchtabs 152 that are configured to be received in corresponding latch slots142 in the cartridge deck 132. In addition, the end base 150 may beprovided with laterally-extending attachment lugs 154 for attaching theend base 150 to the elongate channel 110. For example, the attachmentlugs 154 may be configured to be received in corresponding attachmentholes 112 in the elongate channel 110.

In one form, the end base 150 includes a centrally disposed slot 156that is configured to support a tissue cutting member 160 and sled 170.The tissue cutting member 160 may include a body portion 162 that has atissue cutting portion 164 thereon or otherwise attached thereto. Thebody portion 162 may be threadably journaled on an end effector drivescrew 180 that is rotatably mounted within the elongate channel 110. Thesled 170 is supported for axial travel relative to the end effectordrive screw 180 and may be configured to interface with the body portion162 of the tissue cutting member 160. As the tissue cutting member 160is driven distally, the sled 170 is driven distally by the tissuecutting member 160. As the sled 170 is driven distally, the wedges 172formed thereon serve to advance the drivers 138 upward within the staplecartridge 130.

The end effector 102 may further include an anvil assembly 190 that issupported for selective movement relative to the staple cartridge 130.In at least one form, the anvil assembly 190 may comprise a first anvilportion 192 that is coupled to a rear anvil portion 194 and a top anvilportion 196. The rear anvil portion 194 may have a pair of laterallyprotruding trunnions 198 that are configured to be received incorresponding trunnions holes or cavities 114 in the elongate channel110 to facilitate movable or pivotal travel of the anvil assembly 190relative to the elongate channel 110 and the staple cartridge 130supported therein.

The tissue cutting member 160 may be provided with a pair oflaterally-protruding actuator tabs 166 that are configured to beslidably received within slots 199 in the anvil assembly 190. Inaddition, the tissue cutting member 160 may further have a foot 168 thatis sized to engage a bottom portion of the elongate channel 110 suchthat, as the tissue cutting member 160 is driven distally, the tabs 166and foot 168 cause the anvil assembly 190 to move to a closed position.The tabs 166 and foot 168 may serve to space the anvil assembly 190relative to the staple cartridge 130 at a desired spacing as the tissueis cut and stapled. The first anvil portion 192 may have a stapleforming underside 193 thereon to form the surgical staples 140 as theyare driven into contact therewith. FIG. 4 illustrates the position ofthe anvil assembly 190 and the cutting member 160 when the anvilassembly 190 is in an open position. FIG. 5 illustrates the position ofthe anvil assembly 190 and the cutting member 160 after the anvilassembly 190 has been closed, but before the tissue cutting member 160has been advanced distally or “fired”. FIG. 6 illustrates the positionof the tissue cutting member 160 after it has been advanced to itsdistal-most position within the staple cartridge 130.

The end effector drive screw 180 may be rotatably supported within theelongate channel 110. In one form, for example, the end effector drivescrew 180 may have a proximal end 182 that is coupled to a drive shaftattachment member 184 that is configured to interface with a couplerassembly 200. The drive shaft attachment member 184 may be configured tobe attached to the proximal end 182 of the end effector drive screw 180.For example, the drive shaft attachment member 184 may have ahexagonally-shaped protrusion 186 extending therefrom that is adapted tobe non-rotatably received in a correspond hexagonal socket thatcomprises a portion of a firing system generally designated as 500.Rotation of the end effector drive screw 180 in a first direction causesthe tissue cutting member 160 to move in the distal direction. Invarious forms, the staple cartridge 130 may be fitted with a pair ofbumpers 174 that that serve to cushion the sled 170 as it reaches itsdistal-most position within the elongate channel 110. The bumpers 174may each have a spring 176 to provide the bumper with a desired amountof cushion.

End Effector Coupler Assembly

Various forms of implements 100 may be operably coupled to the surgicalinstrument 10 by means of a coupler assembly 200. One form of couplerassembly 200 is shown in FIGS. 7-14. The coupler assembly 200 mayinclude a coupler housing segment 202 that is configured to operablysupport a drive gear assembly collectively designated as 220. In atleast one form, the drive gear assembly 220 includes an input gear 222,a transfer gear 228, and an output gear 232. See FIG. 8. The input gear222 is mounted to or formed on an input shaft 224 that is rotatablysupported by first and second bulkhead members 204, 206. The input shaft224 has a proximal end 226 that is configured to mate with a distalfiring shaft segment 510 that comprises a portion of a unique and novelfiring system 500 which will be described in further detail below. Forexample, the proximal end 226 may be configured with a hexagonalcross-sectional shape for non-rotatable insertion into ahexagonal-shaped socket 512 formed in a distal end of a distal firingshaft segment 510. The transfer gear 228 may be mounted to or formed ona transfer shaft 230 that is rotatably supported by the baffle members204, 206. The output gear 232 may be mounted to or formed on an outputdrive shaft 234 that is rotatably supported by the baffle members 204,206. For assembly purposes, the distal end 236 of the output drive shaft234 may be configured to be non-rotatably attached to an output socket238 that protrudes distally out through a distal end cap 210. In onearrangement, the distal end cap 210 may be attached to the couplerhousing 202 by fasteners 208 or any other suitable fastenerarrangements. The output socket 238 may be pinned to the distal end 236of the output drive shaft 234. The output socket 238 may be configuredto non-rotatably mate with the drive shaft attachment member 184. Forexample, the output socket 238 may be configured with a hexagonal shapeso that it can mate with the hexagonal protrusion 186 on the drive shaftattachment member 184. In addition, to facilitate operable attachment ofthe implement 100 to the coupler assembly 200, an attachment lug may beformed or attached to the end cap 210.

One arrangement of the coupler assembly 200 may further include alocking assembly generally designated as 240. In at least one form, thelocking assembly 240 includes a spring-biased locking member or pin 242that is movably supported in a locking slot 214 formed in the couplerhousing segment 202. The locking pin 242 may be configured to axiallymove within the locking slot 214 such that its locking end 244 protrudesout through a hole 211 in the end cap 210. See FIG. 8. A locking spring246 is journaled on the locking pin 242 to bias the locking pin 242within the locking slot 214 in the distal direction “DD”. An actuatorarm 248 may be formed on or attached to the locking pin 242 to enablethe user to apply an unlocking motion to the locking pin 242 in theproximal direction “PD”.

As can be seen in FIGS. 3, 9, and 10, the elongate channel 110 of theend effector 102 may have a proximal end wall 116 that has a couplingopening 118 formed therein for receipt of the attachment lug 212therein. In one arrangement, for example, the attachment lug 212 mayinclude a neck portion 213 that has a mushroomed attachment head 215formed thereon. The coupling opening 118 may have a first circularportion 120 sized to enable the attachment head 215 to be insertedtherein. The coupling opening 118 may further have a narrow slot 122formed therein that is sized to enable the neck 213 to be receivedtherein. The proximal end wall 116 may further have a locking hole 124for receiving the distal end 244 of the locking pin 242 therein.

One method of attaching an end effector 102 to the coupling assembly 200of the surgical instrument 10 may be understood from reference to FIGS.12-14. For example, to attach the end effector 102 to the couplingassembly 200, the user may align the hexagonal protrusion 186 on thedrive shaft attachment member 184 with the hexagonal output socket 238.Likewise, the mushroom head 215 may be aligned with the circular openingportion 120 of the coupling opening 118 as illustrated in FIGS. 9 and12. The user may then axially insert the protrusion 186 into the socket238 and the attachment head 215 into the coupling opening 118 as shownin FIG. 13. Thereafter, the user may rotate the end effector 102(represented by arrow “R” in FIG. 14) to cause the neck 213 to enter theslot 122 and enable the distal end 244 of the locking pin 242 to snapinto the locking hole 124 to prevent further relative rotation betweenthe end effector 102 and the coupling assembly 200. Such arrangementserves to operably couple the end effector 102 to the surgicalinstrument 10.

To detach the end effector 102 from the coupling assembly 200, the usermay apply an unlocking motion to the actuator arm 246 to bias thelocking pin the proximal direction “PD”. Such movement of the lockingpin 242 causes the distal end 244 of the locking pin 242 to move out ofthe locking hole 124 in the end wall 116 of the elongate channel 110.The user is then free to rotate the end effector 102 relative to thecoupling assembly in an opposite direction to move the neck portion 213of the attachment button 212 out of the slot 122 to enable theattachment head 215 to be axially pulled out of the coupling opening 118in the end effector 102 to thereby detach the end effector 102 from thecoupling assembly 200. As can be appreciated from above, the couplingassembly 200 provides a unique and novel arrangement for operablycoupling a surgical implement 100 that is operable through applicationof rotary drive motion(s) to the surgical instrument 10. In particular,the coupling assembly 200 enables a variety of different surgicalimplements 100 or end effectors 102 to be operably coupled to theelongate shaft assembly 30 of the surgical instrument 10.

Articulation System

As can be seen in FIGS. 1 and 2, the elongate shaft assembly 30 maydefine a shaft axis A-A. In at least one form, the elongate shaftassembly 30 may include an articulation system 300 for selectivelyarticulating the end effector 102 about an articulation axis B-B that issubstantially transverse to the shaft axis A-A. One form of articulationsystem 300 is shown in FIGS. 15 and 16. As can be seen in those Figures,the articulation system 300 may include a powered articulation joint310. In at least one arrangement, the articulation joint 310 includes adistal joint portion or a distal clevis 312 that is rotatably supportedon a proximally-extending hub portion 203 of the coupler housing segment202 by a distal housing bearing 314. See FIG. 20. The distal clevis 312may be pivotally attached to a proximal joint portion or proximal clevis330 by an articulation pin 332 that defines articulation axis B-B. SeeFIG. 18. The distal clevis 312 may include a distally-protrudingattachment hub 316 that is sized to be received within the proximal endof the coupler housing segment 202. The attachment hub 316 may have anannular groove 318 therein that is configured to receive attachment pins320 therein. See FIG. 8. The attachment pins 320 serve to attach thecoupler housing segment 202 to the distal clevis 312 such that thecoupler housing segment 202 may rotate relative to the distal clevis 312about the shaft axis A-A. As can be seen in FIG. 20, the distal firingshaft segment 510 extends through the hub portion 203 of the couplerhousing segment 202 and is rotatably supported relative thereto by adistal firing shaft bearing 322 mounted within the hub portion 203.

To facilitate the application of a rotary drive or firing motion to theend effector 102, as well as to facilitate rotation of the end effector102 relative to the elongate shaft 30 about the shaft axis A-A whilemaintaining the ability to articulate the end effector 102 relative tothe elongate shaft assembly 30 about articulation axis B-B, thearticulation joint 310 may include a unique and novel “nested” gearassembly, generally designated as 350 and which is located within a geararea 351 between the distal clevis 312 and the proximal clevis 330. SeeFIGS. 18-20. In at least one form, for example, the nested gear assembly350 may include an inner drive shaft gear train or “first gear train”360 that is “nested” with an outer end effector gear train or “secondgear train” 380. As used herein, the term “nested” may mean that noportion of the first gear train 360 extends radially outward beyond anyportion of the second gear train 380. Such unique and novel geararrangement is compact and facilitates the transfer of rotary controlmotions to the end effector while also enabling the distal clevisportion to pivot relative to the proximal clevis portion. As will bediscussed in further detail below, the inner drive shaft gear train 360facilitates the application of rotary drive or firing motions from aproximal firing shaft segment 520 to the distal firing shaft segment 510through the articulation joint 310. Likewise, the outer end effectorgear train 380 facilitates the application of rotary control motions tothe coupler assembly 200 from an end effector rotation system 550 aswill be discussed in further detail below.

In at least one form, for example, the inner drive shaft gear train 360may include a a distal drive shaft bevel gear 362 that may be attachedto the proximal end of the distal firing shaft segment 510 by a screw364. See FIG. 17. The inner drive shaft gear train 360 may also includea proximal drive shaft bevel gear 366 that is attached to the proximalfiring shaft segment 520 by a screw 368. See FIG. 20. In addition, theinner drive shaft gear train 360 may further include a drive shafttransfer gear 370 that is mounted on a transfer gear bearing 374 that ismounted on a transverse gear shaft 372. See FIG. 17. Such inner driveshaft gear train 360 may facilitate the transfer of rotary drive motionsfrom the proximal firing shaft segment 520 through the articulationjoint 310 to the distal firing shaft segment 510.

As indicated above, the nested gear assembly 350 also includes an outerend effector gear train 380 that facilitates the application of rotarycontrol motions to the coupler assembly 200 from the end effectorrotation system 550 through the articulation joint 310. In at least oneform, the outer end effector gear train 380 may, for example, include anoutput bevel gear 382 that is non-rotatably (e.g., keyed) onto theproximally-extending hub portion 203 of the coupler housing segment 202.The outer end effector gear train 380 may further include an input bevelgear 384 that is non-rotatably attached (e.g., keyed onto) to a proximalrotation shaft segment 552 of the end effector rotation system 550. Inaddition, the outer end effector gear train 380 may further include arotation shaft transfer gear 388 that is mounted on an outer transfergear bearing 386 that is supported on the transversely-extendingarticulation pin 332. See FIG. 17. Articulation pin 332 extends throughthe hollow transverse gear shaft 372 and serves to pin the distal clevis312 to the proximal clevis 330 for articulation about the transversearticulation axis B-B. The articulation shaft 332 may be retained inposition by spring clips 334. The unique and novel articulation joint310 and nested gear assembly 350 facilitate the transfer of variouscontrol motions from the handle assembly 20 through the elongate shaftassembly 30 to the end effector 102 while enabling the end effector 102to rotate about the elongate shaft axis A-A and articulate about thearticulation axis B-B.

Articulation of the end effector 102 about the articulation axis B-Brelative to the elongate shaft assembly 30 may be accomplished by anarticulation control system 400. In various forms, the articulationcontrol system 400 may include an articulation control motor 402 that isoperably supported in the handle assembly 20. See FIG. 15. Thearticulation control motor 402 may be coupled to an articulation driveassembly 410 that is operably supported on a detachable drive mount 700that is removably supported in the handle assembly 20 as will bediscussed in further detail below. In at least one form, thearticulation drive assembly 410 may include a proximal articulationdrive shaft segment 412 that is rotatably supported in a shaft housingassembly 710 of the detachable drive mount 700. See FIGS. 27 and 28. Forexample, the proximal articulation drive shaft segment 412 may berotatably supported within a distal shaft housing portion 712 byarticulation bearings 414. In addition, the proximal articulation driveshaft segment 412 may be rotatably supported in a proximal shaft housingportion 714 by bearings 415. See FIG. 28. The articulation controlsystem 400 may further comprise a proximal articulation shaft segment420 that is rotatably driven about the shaft axis A-A by thearticulation control motor 402. As can also be seen in FIG. 15, thearticulation drive assembly 410 may also include a pair of articulationdrive pulleys 416, 417 that serve to drive articulation drive belt 418.Thus, actuation of the articulation control motor 402 may result in therotation of the proximal articulation shaft segment 420 about the shaftaxis A-A. See FIG. 15.

As can be seen in FIGS. 15 and 16, the proximal articulation shaftsegment 420 has a threaded portion 422 that is adapted to threadablymate with an articulation drive link 424. Rotation of the distalarticulation drive shaft segment 420 in a first direction may axiallydrive the articulation drive link 424 in the distal direction “DD” androtation of the distal articulation drive shaft segment 420 in anopposite or second direction may cause the articulation drive link 424to move axially in the proximal direction “PD”. The articulation drivelink 424 may be pinned to an articulation bar 426 by a pin 428. Thearticulation bar 426 may, in turn, be pinned to the distal clevis 312 bypin 429. See FIG. 17. Thus, when the clinician wishes to articulate theend effector 102 or implement 100 about the articulation axis B-Brelative to the elongate shaft assembly 30, the clinician actuates thearticulation control motor 402 to cause the articulation control motor402 to rotate the proximal articulation shaft segment 420 to therebyactuate the articulation bar 426 in the desired direction to pivot thedistal clevis 312 (and end effector 102 attached thereto) in the desireddirection. See FIGS. 21 and 22.

Firing System

As indicated above, the end effector 102 may be operated by rotarycontrolled motions applied to the end effector drive screw 180 by afiring system 500 which includes the distal firing shaft segment 510 andthe proximal firing shaft segment 520. See FIG. 23. The proximal firingshaft segment 520 comprises a portion of the elongate shaft assembly 30and may be rotatably supported within a hollow proximal rotation shaftsegment 552 by a distal bearing sleeve 522. See FIG. 20. Referring againto FIG. 23, in at least one form, the firing system 500 includes afiring motor 530 that is operably supported in the handle assembly 20. Aproximal end of the proximal firing shaft segment 520 may be rotatablysupported within the detachable drive mount 700 and be configured to becoupled to the firing motor 530 in a manner discussed in further detailbelow. As can be seen in FIG. 30, the proximal end of the proximalfiring shaft segment 520 may be rotatably supported in a thrust bearing524 mounted with the distal bulkhead plate 722 of the drive mountbulkhead assembly 720. Actuation of the firing motor 530 will ultimatelyresult in the rotation of the end effector drive screw 180 to apply therotary control motion to the end effector 102.

End Effector Rotation System

In various forms, the surgical instrument 10 may also include an endeffector rotation system or “distal roll system” 550 for selectivelyrotating the end effector 102 relative to the elongate shaft assembly 30about the shaft axis A-A. The end effector rotation system 550 mayinclude the proximal rotation shaft segment 552 which also comprises aportion of the elongate shaft assembly 30. As can be seen in FIG. 20,the proximal rotation shaft segment 552 may be rotatably supportedwithin the proximal clevis 330 by a distal bearing 554 and a proximalbearing 556. In addition, the proximal rotation shaft segment 552 may berotatably supported within the proximal articulation shaft segment 420by a distal bearing sleeve 558 and a proximal bearing 559. See FIGS. 20and 30. The proximal end of the proximal rotation shaft segment 552 mayalso be rotatably supported within a drive mount bulkhead assembly 720by a proximal bearing 555 as can be seen in FIG. 30.

In at least one form, the end effector rotation system 550 may includean end effector rotation or “distal roll” motor 560 that is operablysupported in the handle assembly 20. See FIG. 24. The end effectorrotation motor 560 may be coupled to a rotation drive assembly 570 thatis operably supported on the detachable drive mount 700. In at least oneform, the rotation drive assembly 570 includes a proximal rotation driveshaft segment 572 that is rotatably supported in the shaft housingassembly 710 of the detachable drive mount 700. See FIG. 27. Forexample, the proximal rotation drive shaft segment 572 may be rotatablysupported within the distal shaft housing portion 712 by bearings 576.In addition, the proximal rotation drive shaft segment 572 is rotatablysupported in the proximal housing portion 714 by bearing 577. See FIG.28. As can be seen in FIGS. 24 and 28, the rotation drive assembly 570may also include a pair of rotation drive pulleys 574, 575 that serve todrive a rotation drive belt 578. Thus, actuation of the end effectorrotation motor 560 will result in the rotation of the proximal rotationshaft segment 552 about the shaft axis A-A. Rotation of the proximalrotation shaft segment 552 results in rotation of the coupler assembly200 and ultimately of the end effector 102 coupled thereto.

Shaft Rotation System

Various forms of the surgical instrument 10 may also include a shaftrotation system generally designated as 600. The shaft rotation systemmay also be referred to herein as the “proximal roll system”. In atleast one form, the shaft rotation system 600 includes a proximal outershaft segment 602 that also comprises a portion of the elongate shaftassembly 30. The proximal outer shaft segment 602 has a distal end 604that is non-rotatably coupled to the proximal clevis 330. As can be seenin FIGS. 19 and 26, the distal end 604 has a clearance notch 606 thereinfor permitting actuation of the articulation bar 426 relative thereto.The shaft rotation system 600 may include a shaft rotation or “proximalroll” motor 610 that is operably supported in the handle assembly 20.The shaft rotation motor 610 may be coupled to a shaft drive assembly620 that is operably supported on the detachable drive mount 700. In atleast one form, the shaft drive assembly 620 includes a proximal driveshaft segment 622 that is rotatably supported in the distal shafthousing portion 712 of the detachable drive mount 700 by bearings 624.See FIG. 28. In addition, the proximal drive shaft segment 622 isrotatably supported in the proximal drive shaft housing portion 714 bybearing 626. As can be seen in FIGS. 26 and 28, the shaft drive assembly620 may also include a pair of rotation drive pulleys 630, 632 thatserve to drive a shaft drive belt 634. The drive pulley 632 isnon-rotatably attached to the proximal drive shaft segment 602 such thatrotation of the drive pulley 632 results in rotation of the proximaldrive shaft segment 602 and the end effector 102 attached thereto aboutthe shaft axis A-A. As can be further seen in FIGS. 28 and 30, theproximal drive shaft segment 602 is rotatably supported within thedistal shaft housing portion 712 by a pair of sleeve bearings 607 and608.

The unique and novel articulation system arrangements of the presentinvention afford multiple degrees of freedom to the end effector whilefacilitating the application of rotary control motions thereto. Forexample, in connection with some surgical operations, positioning of theend effector into a position that is coplanar with the target tissue maybe necessary. Various arrangements of the present invention offer atleast three degrees of freedom to an end effector while meeting sizelimitations often encountered when performing surgical procedureslaparoscopically, for example.

Various forms of the present surgical instrument facilitate improveduser dexterity, precision, and efficiency in positioning the endeffector relative to the target tissue. For example, conventional shaftarticulation joints commonly used for power transmission frequentlyemploy universal joints(s), hinged vertebral and flexurally compliantcouplings. All of those methods may tend to suffer from performancelimitations including limits in bend radius and excessive lengthcharacteristics. Various forms of the unique and novel elongate shaftassemblies and drive systems disclosed herein, for example, allow thedistance between the articulation axis and the end effector to beminimized when compared to other conventional articulation arrangements.The elongate shaft assemblies and articulation joint arrangementsdisclosed herein facilitate transfer of at least one rotary controlmotion to the end effector while also affording multiple degrees offreedom to the end effector to enable the end effector to be preciselypositioned relative to the target tissue.

After the end effector 102 or implement 100 has been used, it may bedetached from the coupler assembly 200 of the surgical instrument 10 andeither disposed of or separately reprocessed and sterilized utilizingappropriate sterilization methods. The surgical instrument 10 may beused multiple times in connection with fresh end effectors/implements.Depending upon the particular application, it may be desirable for thesurgical instrument 10 to be resterilized. For example, the instrument10 may be resterilized before it is used to complete another surgicalprocedure.

Surgical instruments must be sterile prior to use. One popular methodfor sterilizing medical devices involves exposing the device to wetsteam at a desired temperature for a desired time period. Suchsterilization procedures, while effective, are generally ill-suited forsterilizing surgical instruments that employ electrical components dueto the high temperatures generated when using steam sterilizationmethods. Such devices are commonly sterilized by exposing them to a gassuch as, for example, Ethylene Oxide.

Various forms of the surgical instrument 10 may be sterilized utilizingconventional sterilization methods. In at least one form, for example,the elongated shaft assembly 30 may be fabricated from components andmaterials that may be effectively sterilized utilizing methods thatemploy relatively high sterilization temperatures. It may be desirable,however, to use sterilization methods that have lower operatingtemperatures when sterilizing the handle assembly, for example, to avoidpossibly damaging the electrical components. Thus, it may be desirableto sterilize the handle assembly 20, which houses various electricalcomponents, apart from the elongate shaft assembly 30. To facilitate useof such separate sterilization procedures, the elongate shaft assembly30, in at least one form, is detachable from the handle assembly 20.

Detachable Drive Mount Assembly

More specifically and with reference to FIG. 28, the detachable drivemount assembly 700 is operably supported within a portion of the handleassembly 20. In one form, for example, the detachable drive mountassembly 700 may be mounted within distal handle housing segments 21 and22 that may be interconnected by means of snap features, screws or otherfastener arrangements. The distal handle housing segments 21 and 22 whencoupled together may be referred to herein as a “distal handle housingportion” or “housing” 25. The detachable drive mount assembly 700 may,for example, include a shaft housing assembly 710 that comprises adistal shaft housing 712 and a proximal shaft housing 714. Thedetachable drive mount assembly 700 may further comprise a drive mountbulkhead assembly 720 that includes a distal bulkhead plate 722 and aproximal coupler bulkhead plate 724. As was described above, in at leastone form, the detachable drive mount assembly 700 may operably supportthe articulation drive assembly 410, the proximal end of the proximalfiring shaft segment 520, the rotation drive assembly 570, and the shaftdrive assembly 620. To facilitate quick coupling of the firing shaftsegment 520, the articulation drive assembly 410, the rotation driveassembly 570, and the shaft drive assembly 620 to the firing motor 530,the articulation control motor 402, the end effector rotation motor 560and the shaft rotation motor 610, respectively, a unique and novelcoupler arrangement may be employed.

Motor Mounting Assembly

In at least one form, for example, the detachable drive mount assembly700 may be configured to be removably coupled to a motor mountingassembly generally designated as 750. The motor mounting assembly 750may be supported within handle housing segments 23 and 24 that arecouplable together by snap features, screws, etc. and serve to form apistol grip portion 26 of the handle assembly 20. See FIG. 1. The handlehousing segments 23 and 24, when coupled together, may be referred toherein as a “proximal handle housing portion” or “housing” 28. Referringto FIGS. 29-32, the motor mounting assembly 750 may comprise a motormount 752 that is removably supported within the handle housing segments23 and 24. In at least one form, for example, the motor mount 752 mayhave a bottom plate 754 and a vertically extending motor bulkheadassembly 756. The bottom plate 754 may have a fastener tab 758 formedthereon that is configured to retainingly mate to be received with abottom plate portion 730 of the detachable drive mount 700. In addition,a right locator pin 772 and a left locator pin 774 are mounted in themotor bulkhead assembly 756 and protrude distally therethrough incorresponding right and left socket tubes 716, 718 formed in theproximal shaft housing portion 714. See FIG. 32.

In at least one configuration, the detachable drive mount assembly 700may be removably coupled to the motor mounting assembly 750 byreleasable latch arrangements 760. As can be seen in FIG. 31, forexample, a releasable latch arrangement 760 may be located on eachlateral side of the motor mounting assembly 750. Each releasable latcharrangement 760 may include a latch arm 762 that is pivotally attachedto the motor bulkhead assembly 756 by a corresponding pin 764. Eachlatch arm 762 may protrude out through a corresponding fastener lug 766formed on the distal side of the motor bulkhead assembly 756. Thefastener lugs 766 may be configured to be slidably received withincorresponding receiver members 726 that protrude proximally from theproximal coupler bulkhead plate 724. See FIGS. 30 and 32. When the drivemount assembly 700 is brought into mating engagement with the motormounting assembly 750, the fastener lugs 766 are slid into thecorresponding receiver members 726 such that the latch arms 762retainingly engage a latch portion 728 of the corresponding receivermember 726. Each latch arm 762 has a corresponding latch spring 768associated therewith to bias the latch arm 762 into retaining engagementwith the corresponding latch portion 728 to retain the detachable drivemount assembly 700 coupled to the motor mounting assembly 750. Inaddition, in at least one form, each latch arrangement 760 furtherincludes a release button 770 that is movably coupled to the motorbulkhead 756 and is oriented for selective contact therewith. Eachrelease button 770 may include a release spring 771 that biases thebutton 770 out of contact with its corresponding latch arm 762. When theclinician desires to detach the detachable drive mount assembly 700 fromthe motor mounting assembly 750, the clinician simply pushes each button770 inwardly to bias the latch arms 762 out of retaining engagement withthe latch portions 728 on the receiver members 726 and then pulls thedetachable drive mount assembly 700 out of mating engagement with themotor mounting assembly 750. Other releasable latch arrangements may beemployed to releasably couple the detachable drive mount assembly 700may be removably coupled to the motor mounting assembly 750.

At least one form of the surgical instrument 10 may also employ couplerassemblies for coupling the control motors to their respective driveassemblies that are operably supported mounted on the detachable drivemount 700. More specifically and with reference to FIGS. 28-32, acoupler assembly 780 is employed to removably couple the articulationdrive assembly 410 to the articulation control motor 402. The couplerassembly 780 may include a proximal coupler portion 782 that is operablycoupled to the drive shaft 404 of articulation control motor 402. Inaddition, the coupler assembly 780 may further include a distal couplerportion 784 that is attached to the proximal articulation drive shaft412. See FIGS. 28 and 32. Each distal coupler portion 784 may have aplurality of (three are shown) coupler protrusions 786 that are designedto non-rotatably seat with corresponding scalloped areas 788 formed inthe proximal coupler portion 782. See FIG. 30. Similarly, another distalcoupler portion 784 may be attached to the proximal rotation drive shaft572 of the rotation drive assembly 570 and a corresponding proximalcoupler portion 782 is attached to the rotation motor drive shaft 562.In addition, another distal coupler portion 784 may be attached to theproximal firing shaft segment 520 and a corresponding proximal couplerportion 782 is attached to the firing motor drive shaft 532. Stillanother distal coupler portion 784 may be attached to the proximal driveshaft segment 622 of the shaft drive assembly 620 and a correspondingproximal coupler portion 782 is attached to the drive shaft 612 of theshaft rotation motor 610. Such coupler assemblies 780 facilitatecoupling of the control motors to their respective drive assembliesregardless of the positions of the drive shafts and the motor shafts.

The various forms of the unique and novel handle assembly arrangementdescribed above enable the elongate shaft assembly 30 to be easilydetached from the remaining portion of the handle assembly 20 thathouses the motors 402, 530, 560 and 610 and the various electricalcomponents comprising a control system, generally designated as 800. Assuch, the elongate shaft assembly 30 and the detachable drive mountportion 700 may be sterilized apart from the remaining portion of handleassembly housing the motors and control system which may be damagedutilizing sterilization methods that employ high temperatures. Suchunique and novel detachable drive mount arrangement may also be employedin connection with arrangements wherein the drive system (motors andcontrol components) comprise a portion of a robotic system that may ormay not be hand held.

Gear Driven Drive Mount Arrangement

FIGS. 100-103 illustrate an alternative drive mount 5700 that employs acollection of gear drives for transmitting drive motions from the motorsto their respective shafts. As can be seen in FIG. 100, the drive mount5700 may include a distal shaft housing assembly 5710 that includes adistal shaft housing 5712 that operably supports a plurality of geartrain arrangements. The distal shaft housing 5712 is configured to beremovably mounted to the proximal coupler bulkhead plate 5724 that has apair of mounting sockets 5725 for receiving corresponding mounting lugs5713 protruding from the distal shaft housing 5712 as can be seen inFIG. 100. As in the above described arrangements, the shaft of thefiring or transection motor 530 is directly coupled to the proximalfiring shaft segment 5520 by a coupler assembly 5780 as can be seen inFIG. 103. The proximal rotational shaft segment 5552 of the end effectorrotation system 550 is rotated by a gear train, generally depicted as5565. In at least one form, for example, the gear train 5565 includes adriven gear 5566 that is attached to the proximal rotational shaftsegment 5552 and is supported in meshing engagement with a drive gear5567. As can be most particularly seen in FIG. 103, the drive gear 5567is mounted to a spur shaft 5568 that is rotatably supported in thedistal shaft housing 5712. The spur shaft 5568 is coupled to the shaftof the end effector rotation or distal roll motor 560 by a couplerassembly 5780.

The proximal articulation shaft segment 5420 is rotated by a gear train,generally depicted as 5430. In at least one form, for example, the geartrain 5430 includes a driven gear 5432 that is attached to the proximalarticulation shaft segment 5420 and is supported in meshing engagementwith a drive gear 5434. As can be most particularly seen in FIG. 102,the drive gear 5434 is mounted to a spur shaft 5436 that is rotatablysupported in the distal shaft housing 5712. The spur shaft 5436 iscoupled to the shaft of the articulation control motor 402 by a couplerassembly 5780.

The proximal outer shaft segment 5602 is rotated by a gear train,generally depicted as 5640. In at least one form, for example, the geartrain 5640 includes a driven gear 5642 that is attached to the proximalouter shaft segment 5602 and is supported in meshing engagement with acompound bevel gear 5644 that is rotatably supported within the distalshaft housing 5712. The compound bevel gear 5644 is in meshingengagement with a drive bevel gear assembly 5646 that is mounted to aspur shaft 5648 that is also rotatably supported in the distal shafthousing 5712. The spur shaft 5648 is coupled to the shaft of the shaftrotation or proximal roll motor 610 by a coupler assembly 5780. See FIG.101. The alternative drive mount 5700 motors and gear trains may be usedto power and control the surgical instrument in the manners hereindescribed.

Power and Control Systems

In various forms, the surgical instrument 10 may employ a control systemgenerally designated as 800 for controlling the various motors employedby the instrument. The motors 402, 530, 560 and 610 and their relatedcontrol components may also be referred to herein as a “drive system”,generally designated as 398. In one form, the drive system 398 serves to“electrically generate” a plurality of control motions. The term“electrically generate” refers to the use of electrical signals toactuate a motor or other electrically powered device and may bedistinguished from control motions that are manually or otherwisemechanically generated without the use of electrical current. In oneform, the drive system 398 may be operably supported within a handleassembly that may be held in the hand or hands of the clinician. Inother forms, however, the drive system 398 may comprise a part of and/orbe operated by and/or be supported by a robotic system.

In one form, the motors 402, 530, 560 and 610 and their related controlcomponents may receive power from a battery 802 that is housed withinthe pistol grip portion 26 of the handle assembly 20. In otherarrangements, the battery may be supported by a robotic system, forexample. In other embodiments, however, the handle assembly 20 may havea power cord (not shown) protruding therefrom for supplying power fromanother source electrical power. In still other arrangements, the motorsand electrical components may receive power and control signals from arobotic system. The control system 800 may comprise various controlsystem components that may include, for example, a distal circuit board810 that is supported on the detachable drive mount 700. The distalcircuit board 810 may include electrical connectors 812 and/orelectrical components that can be sterilized utilizing conventionalsteam sterilization techniques as well as by other lower temperaturesterilization methods. The control system 800 may further include aproximal circuit board 820 that is supported in the portion of thehandle assembly 20 formed by the handle housings segments 23 and 24. Theproximal circuit board 820 is configured to be electrically coupled tothe distal circuit board 810 when the detachable drive mount 700 hasbeen coupled to the motor mounting assembly 750.

Various forms of the surgical instrument 10 may employ a unique andnovel control switch arrangement 830 that may be operably housed withinor supported by the pistol grip portion 26 of the handle assembly 20.For example, in at least one form, the control switch arrangement 830may include a unique and novel joystick control 840 that enables theuser to maximize functional control of various aspects of the surgicalinstrument 10 through a single interface. More specifically and withreference to FIGS. 33-39, one form of joystick control 840 may include ajoystick control rod 842 that is operably attached to a joystick switchassembly 850 that is movably housed within a switch housing assembly844. The switch housing assembly 844 may be mounted within the pistolgrip portion 26 of the handle assembly 20. In at least one form, forexample, the switch housing assembly 844 may include a housing body 846and a rear housing plate 848. As can be most particularly seen in FIGS.35-39, a joystick printed circuit board 852 may be operably supported onthe joystick switch assembly 850 by a rear mounting plate 854. The rearmounting plate 854 may be configured to move as a unit with the joystickswitch assembly 850 and joystick printed circuit board 852 within theswitch housing 844. A joystick spring 856 may be supported between therear housing plate 848 and the rear mounting plate 854 to bias thejoystick switch assembly 850 and joystick control rod 842 in the forwardor distal direction. See FIGS. 36 and 38.

The joystick control 840 may be electrically coupled to the proximalcircuit board 820 and battery 802 of the control system 800 throughvarious connector cables 864 for providing control power to the variousmotors 402, 530, 560, and 610 of the surgical instrument 10. Forexample, by rocking or otherwise actuating the joystick control rod 842,the user may control the articulation control motor 402 and/or thedistal roll motor 560 and/or the proximal roll motor 610.

The joystick control switch assembly 850 may be referred to herein as a“first switch” for controlling one or more of the motors of the drivesystem. The joystick control 840 may further include a first sensor 860which may comprise, for example, a magnet, that may be mounted to thejoystick printed circuit board 852 for movable travel therewith. Inaddition, a second or stationary sensor 862 may be mounted within therear housing plate 848. The second sensor 862 may comprise, for example,a “hall effect” sensor or similar sensing device. In at least onearrangement for example, the sensor 862 may be configured to communicatewith the firing motor 530. The first and second sensors, 860, 862 may bereferred to herein as a “second switch” generally designated as 858. Theabove-described arrangement allows the joystick switch assembly 850 toaxially move in and out when the user depresses the joystick control rod842. By leveraging the in and out motion of the entire joystick switchassembly 850, in at least one form, the design essentially consists of aswitch within a switch. In an unactuated position, the joystick spring856 biases the joystick switch assembly 850 in the forward (distal)direction. When the clinician pushes the joystick 842 inwardly(proximally), the first sensor 860 is moved closer to the second sensor862. Moving the first sensor 860 closer to the second sensor 862 mayresult in the actuation of the so-called second switch 858 which mayresult in the actuation of the transection or firing motor 530.

When performing a procedure using an end effector 102, the clinician maywish to open and close the anvil assembly 190 to manipulate the targettissue into a desired position without transecting or cutting thetissue. In one form, as the clinician initially depresses the joystickcontrol rod 842, the second switch 858 causes the firing motor 530 to beactivated to thereby cause the tissue cutting member 160 to start tomove distally. In various forms, the tissue cutting member 160 isarranged within the end effector 102 such that initial movement of thetissue cutting member 160 in the distal direction causes the anvilassembly 190 to close (i.e., pivot toward the staple cartridge 130without cutting the tissue or firing the surgical staples). When theclinician releases the joystick control rod 842, the joystick spring 856will bias the joystick assembly 850 distally to thereby move the firstsensor 860 away from the second sensor 862. Movement of the sensor 860away from the second sensor 862 may reduce the rotational speed of thefiring motor 530 until the firing motor 530 is eventually stopped ordeactivated. In at least one form, this second switch arrangement 858may be configured such that the rotational speed of the firing motor 530is directly proportional to the speed at which the user depresses thejoystick control rod 842.

Once the clinician has positioned and captured the desired tissue withinthe end effector 102, the end effector 102 may be actuated or “fired” byfully depressing the joystick control rod 842. In various forms, thejoystick switch assembly 850 may also have a third compression switch866 integrally formed therein and which also communicates with thecontrol system 800. Full depression of the joystick control rod 842 mayresult in the activation of the third switch 866. In at least one form,when the third switch 866 is activated, the firing motor 530 will remainactivated even when the clinician releases the joystick control rod 842.After the firing stroke has been completed (i.e., the tissue cuttingmember 160 has been driven to its distal-most position in the endeffector 102), the user may again fully depress the joystick control rod842 to release the third switch 866 and thereby return control of thefiring motor 530 to the second switch 858. Thus, if the clinicianreleases the joystick control rod 842 after completely depressing it forthe second time, the joystick spring 856 will bias the joystick switchassembly 850 to the starting position. The control system 800 will causethe firing motor 530 to rotate in an opposite direction until the tissuecutting member 160 has been returned to its starting position wherebythe anvil assembly 190 is once again moved to an open position to enablethe end effector 102 to release the transected tissue.

In various forms, the switch arrangement 830 may also employ a uniqueand novel thumbwheel control assembly 870. As can be seen in FIG. 42,the thumbwheel control assembly 870 may be rotatably mounted on adistally protruding hub portion 845 of the switch housing assembly 844such that the thumbwheel control assembly 870 is pivotable about aswitch axis SA-SA. Such position conveniently places a thumbwheelactuator member 872 of the thumbwheel control assembly 870 in a positionwherein the clinician can pivot it with a thumb and/or index fingerwhile grasping the pistol grip portion 26 of the handle assembly 20. Thethumbwheel actuator member 872 may be attached to a thumbwheel collar874 that is received on the hub portion 845 and may be rotatablyretained in position by a mounting flange 27 formed by the handlesegments 23 and 24. A left sensor (magnet) 876 and a right sensor(magnet) 878 are mounted to the thumbwheel collar 874 as shown in FIG.41. The sensors 876 and 878 may have opposing polarities. A stationarysensor 880 may be mounted to the switch housing assembly 844 such thatit is centrally disposed between the left sensor 876 and the rightsensor 878. The stationary sensor 880 may comprise, for example, a “halleffect’ sensor and be coupled to the proximal circuit board 820 of thecontrol system 800 for controlling one of the control motors. Forexample, the thumbwheel control assembly 870 may be used to control, forexample, the proximal roll or shaft rotation motor 610. In otherarrangements, the thumbwheel control assembly 870 may be used to controlthe distal roll motor 560 to rotate the end effector about the shaftaxis relative to the elongate shaft assembly. A pair of centeringsprings 882 may be employed to bias the thumbwheel collar 874 into acentral or neutral position. When the thumbwheel collar 874 is in theneutral position as shown in FIG. 41, the shaft rotation or proximalroll motor 610 (or distal roll motor 560—whichever the case may be) isdeactivated.

As the user pivots the thumbwheel actuator 872 in a clockwise directionto a position shown in FIG. 43, the control system 800 may cause theshaft rotation motor 610 to rotate the elongate shaft assembly 30 aboutthe shaft axis A-A in a clockwise direction. Likewise, when the userpivots the thumbwheel actuator 872 in a counterclockwise direction tothe position shown in FIG. 44, the control system 800 may cause theshaft rotation motor 610 to rotate the elongate shaft assembly 30 in thecounterclockwise direction about the shaft axis A-A. Stated another way,as the user pivots the thumbwheel actuator 872 clockwise orcounterclockwise, the stationary sensor 880 controls the rotationaldirection of the elongate shaft assembly 30 based upon the proximity ofthe left and right sensors 876, 878 in relationship to the stationarysensor 880. The response of the stationary sensor 880 can be configuredso that, as the user increases rotation of the thumbwheel actuator 872,the relative speed that the motor 610 rotates the elongate shaftassembly 30 increases. As can be seen in FIGS. 41-44, a stop lug 847 maybe formed on the switch housing assembly 844 to cooperate with a notch875 in the thumbwheel collar to prevent contact between the movablesensors 876, 878 and the stationary sensor 880. Those of ordinary skillin the art will understand that the thumbwheel control assembly 870 maybe used to control any of the other motors of the surgical instrument10. Similarly, the joy stick control 840 may be configured to controlany one or more of the motors in the surgical instrument 10. The uniqueand novel thumbwheel control assembly arrangements disclosed hereinenable the user to have functional control through rotation of anergonomic thumbwheel actuator interface. In alternative forms, themovable sensors 876, 878, may comprise hall effector sensors that eachcommunicate with the motor. The stationary sensor 880 may comprise amagnet.

In various forms, each of the motors of the surgical instrument 10 maybe provided with a corresponding encoder that communicates with amicroprocessor chip on the proximal circuit board 820. For example, thearticulation control motor 402 may have an encoder 404 operably coupledthereto that communicates with the proximal circuit board 820. Thefiring or transection motor 530 may have an encoder 534 operably coupledthereto that communicates with the proximal circuit board 820. The endeffector rotation or distal roll motor 560 may have an encoder 564operably coupled thereto that communicates with the proximal circuitboard 820. The shaft rotation or proximal roll motor 610 may have anencoder 614 operably coupled thereto that communicates with the proximalcircuit board 820. The encoders may serve to provide the correspondingmicroprocessor chips with feedback regarding the number of rotations anddirection of rotation for each of the motors. In some forms, in additionto the encoders, the rotation drive assembly 570 may employ sensorarrangements to track the rotation of the various shaft segments. Forexample, as can be seen in FIGS. 15, 28, and 29, the articulation drivepulley 417 may have a first articulation sensor 419 mounted thereto thatis adapted to be detected by a second articulation sensor 421 which maycomprise, for example, a hall effect sensor, that is mounted to thedistal circuit board 810. The first and second articulation sensors 419,421 serve to provide an additional means of feedback for tracking therotatable position of the proximal articulation shaft 420. Likewise, thedistal roll pulley 575 of the rotation drive assembly 570 may have afirst distal roll sensor 580 mounted thereto that is adapted to bedetected by a second distal roll sensor 582 that is mounted to thedistal circuit board 810. See FIGS. 24, 28, and 29. The first and seconddistal roll sensors 580, 582 serve to provide an additional means offeedback for tracking the rotatable position of the proximal rotationshaft segment 552. In addition, the pulley 632 of the proximal rolldrive assembly 620 may have a first proximal roll sensor 634 that isadapted to be detected by a second proximal roll sensor 636 mounted tothe distal circuit board 810. See FIGS. 26, 28, and 29. The first andsecond proximal roll sensors 634, 636 serve to provide an additionalmeans of feedback for tracking the rotatable position of the proximalouter shaft segment 602.

Conductive Pathways from End Effector to Handle Assembly

As discussed herein, various forms of the surgical instrument 10 may beeffectively employed with a variety of different end effectors orsurgical implements that require or employ rotary or other motions forend effector/implement operation/manipulation. For example, one form ofthe end effector 102 requires rotary control motions to open and closethe anvil assembly 190, drive the surgical staples and transect tissue.One form of the end effector 102 may also be equipped with a distalsensor arrangement for sensing a degree or amount of closure attained bythe anvil assembly 190 relative to the surgical staple cartridge 130.For example, the anvil assembly 190 may include a first anvil sensor 890that is mounted in the distal end thereof. See FIG. 3. The anvil sensor890 may comprise, for example, a hall effector sensor that is configuredto detect a second staple cartridge sensor (magnet) 892 mounted in thedistal end of the surgical staple cartridge 130. In at least one form,the first anvil sensor 890 may communicate with at least one an endeffector conductor 894 that is mounted on the anvil assembly 190 asshown. In one form for example, the end effector conductor 894 comprisesa flat metal strip that has a flexible hook 896 formed on the proximalend thereof. As generally used herein, the terms “conductor” or“conductive” refer to a member or component that is capable ofconducting electricity therethrough. A conductor, for example, maycomprise wire or wires, flexible conductive strips or metal traces,multi-channel conductive ribbon cable, etc. As used herein, the terms“electrically contacts” and “electrically communicates with” means thatthe components are configured to pass electrical current or signalstherebetween.

Referring now to FIGS. 45 and 46, it can be seen that the flexible hook896 may be oriented for contact with the distal end 244 of the lockingpin 242. The locking pin 242 may, for example, be constructed fromelectrical conductive material and be coated with an insulative coating(e.g., polymer, etc.) to electrically insulate the locking pin 242 fromthe coupler housing segment 202 but have an exposed tip configured tomake electrical contact with the hook 896. In addition, the lockingspring 246 may also be fabricated from an electrical conductive material(e.g., metal). The locking spring 246 may be attached (e.g., soldered,etc.) to the locking pin 242 such that the locking pin 242 and lockingspring 246 form an electrically conductive coupler pathway forconducting electrical current through the coupler assembly 200. Thelocking spring 246 may also be coated with an insulative coating toelectrically insulate it from the coupler housing segment 202. Thelocking pin 242 and the locking spring 246 may be collectively referredto herein as a “locking pin assembly” 249. The locking spring 246 mayterminate in a proximal end 247 that is configured for slidableelectrical contact with a proximal conductor assembly 250 that ismounted to the distal clevis 312 of the articulation joint 310.

As can be seen in FIG. 8, one form of proximal conductor assembly 250may include conductor wire/wires/trace 252 and an annular electricalconductor in the form of, for example, a conductive washer 254. As canbe seen in FIG. 46, the conductor 252 communicates with a proximalconductor portion 256 that protrudes out through the distal clevis 312to communicate with an articulation joint conductor 258 supported by aflexible joint cover 900 that extends over the articulation joint 310.In at least one form, the joint cover 900 includes a hollow body 902that has an open proximal end 904 and an open distal end 906 and a jointreceiving passage 908 extending therebetween. The hollow body 902 maycontain a plurality of ribs 910 and be fabricated from a polymer orsimilar non-electrically-conductive material that is omni-directionallystretchable to accommodate movement of the articulation jointcomponents. However, the joint cover 900 could also be fabricated fromother suitable materials and arrangements such as flexible micro-cuttubing, etc. The articulation joint conductor 258 may comprise forexample, a conductive ribbon cable, wire, wires, trace, etc. As can befurther seen in FIG. 46, a proximal end of the articulation jointconductor 258 is electrically coupled to a shaft conductor 260 on theproximal outer shaft segment 602.

Referring now to FIGS. 47 and 48, in at least one form, the proximal endof the shaft conductor 260 may be oriented for sliding contact with anannular conductor ring 262 that is mounted in the handle assembly 20.Such arrangement may enable electrical current to flow between the shaftconductor 260 and the conductor ring 262 as the elongate shaft assembly30 is rotated about the shaft axis A-A relative to the handle assembly20. As can be further seen in FIGS. 47 and 48, a conductor 264 iscoupled to the conductor ring 262 and extends proximally through thehandle housing 20. The conductor 264 may comprise a wire or othersuitable electrical conductor and have a proximal end 266 that isconfigured to flexibly contact the tip of the left locator pin 774. Inparticular, for example, the proximal end 266 may extend through thewall of the left locator socket 718 such that when the left locator pin774 is inserted therein, the proximal end portion 266 of the conductor264 makes contact with the left locator pin 774. In at least one form,the left locator pin 774 is fabricated from electrically conductivematerial (metal) such that when the proximal end 266 of the conductor264 makes contact therewith, electrical current can flow between thosecomponents. In addition, an attachment conductor 776 serves toelectrically couple the left locator pin 774 to the proximal circuitboard assembly 820 to facilitate transfer of electrical currenttherebetween.

The above-described arrangement facilitates the passage of electricalcurrent between the end effector or surgical implement that has beenattached to the elongate shaft assembly 30 of the surgical instrument 10and the control system components located in the handle assembly 20 ofthe surgical instrument 10. This conductive pathway is maintained whilealso maintaining the ability to rotate the end effector relative to theelongate shaft assembly, articulate the end effector relative to theelongate shaft assembly and rotate the end effector and elongate shaftassembly as a unit. The joint cover 900 may provide an electricalcommunication path between the elongate shaft and the end effector. Thejoint cover 900 may contain an electrical flex strip, wire, trace, etc.to conduct more than one signal for electrical communication. Thus, aplurality of different sensors or electrical components may be employedin the end effector to provide various forms of feedback to the user.For example, sensors may be employed determine the number of use cycles,track the progress of the cutting instrument within the end effectorduring firing, provide feedback to the control system to automaticallycontrol the various motors in the handle assembly, etc.

FIG. 49 illustrates an alternative articulation joint 310′ that isconfigured to permit the passage of electrical current or signalstherethrough. In this form, a distal electrical joint conductor 270 isprovided through the distal clevis 312′ to contact a distal metal washer272 embedded therein as shown. The proximal clevis 330′ may have aproximal metal washer 274 mounted thereto for rotational contact withthe distal metal washer 272 when the distal clevis 312′ is coupled tothe proximal clevis 330″ in the manner described above. The proximalmetal washer 274 may be curved or beveled to maintain sliding contactbetween the washers 272, 274. A proximal electrical joint conductor 276in the form of, for example, a contactor strip, wire or trace isattached to the washer 274 and is configured for electrical contact withthe shaft conductor 260 on the proximal outer shaft segment 602. Thus,such arrangement facilitates the passage of electrical current/signalsfrom the end effector 102 through the locking pin 242, locking spring242 (i.e., the locking pin assembly 249), conductor ring 252, distalelectrical joint conductor 270, washers 272, 274 and the proximalelectrical joint conductor 276 to the shaft conductor 260.

Alternative Articulation Joint Arrangements

Another form of articulation joint 1000 is shown in FIGS. 50-53. Sucharticulation joint 1000 can facilitate the articulation and rotation ofan end effector or surgical implement coupled thereto relative to theshaft axis A-A of the elongate shaft to which the articulation joint1000 is attached. The articulation joint may also facilitate suchmovement of the end effector or surgical implement while also providinga rotary control motion to the end effector/implement for actuation ormanipulation thereof. The articulation joint 1000 may be coupled to anelongate shaft assembly that is similar in construction to the elongateshaft assembly 30 described above or it may be coupled to other suitableshaft assemblies. The elongate shaft assembly may be coupled to a handleassembly that houses a plurality of motors. One motor may be used toapply control motions to a flexible cable member 1010 that extendsthrough the elongate shaft assembly and which is operably coupled to thearticulation joint 1000. For example, the flexible cable 1010 may beattached to a sheave or pulley assembly that is operably attached to orcommunicates with the shaft of a corresponding motor such that operationof the motor causes the cable 1010 to be actuated. The handle assemblymay also include a firing motor that is operably attached to a proximalfiring shaft 1030 that extends through the elongate shaft assembly tointerface with the articulation joint 1000 as will be discussed infurther detail below. The handle assembly may also include a motor thatoperably interfaces with an end effector or distal roll shaft 1040 thattransmits a rotary control motion to the articulation joint 1000 whichmay be used to rotate the end effector or surgical implement about theshaft axis A-A relative to the elongate shaft. The handle assembly mayalso include a proximal roll motor that is employed to rotate theelongate shaft assembly about the shaft axis A-A in the manner describedabove.

In at least one form, the articulation joint 1000 may include a proximalclevis assembly 1020 that is attached to or formed on the end of theelongate shaft assembly. In the arrangement shown in FIGS. 50-53, theproximal clevis assembly 1020 is formed on a distal end of the elongateshaft assembly 30′. As can be seen in those Figures, the proximal clevisassembly 1020 has a distal end wall 1022 and a pair of spaced clevisarms 1024, 1026. The proximal clevis 1020 is configured to be pivotallycoupled to a distal clevis 1050 by a pivot shaft 1051 which serves todefine articulation axis B-B. Articulation axis B-B may be substantiallytransverse to shaft axis A-A.

The distal clevis 1050 has a socket 1052 formed thereon and a pair ofdistal clevis arms 1054, 1056. The pivot shaft 1051 extends centrallythrough the clevis arms 1024, 1054, 1056, and 1026 as shown in FIG. 53.The clevis arm 1054 may have a cable pulley 1058 formed thereon to whichthe flexible cable 1010 is attached. Thus, rotation of the cable 1010 byits corresponding motor will result in rotation of the distal clevis1050 relative to the proximal clevis 1020 about the articulation axisB-B.

In various forms, the articulation joint 1000 may further include arotatable mounting hub 1060 that is rotatably received within the socket1052. The mounting hub 1060 may have a ring gear 1062 attached theretothat is adapted for meshing engagement with a distal roll pinion gear1064. The distal roll pinion gear 1064 is attached to a pinion shaft1066 that is rotatably supported in an end wall 1053 of the distalclevis 1050. The pinion shaft 1066 has a distal roll output gear 1068attached thereto. The distal roll output gear 1068 is supported inmeshing engagement with distal roll transfer gear 1070 that is rotatablyjournaled on the pivot shaft 1051 and is in meshing engagement with adistal roll input gear 1072. The distal roll input gear 1072 is mountedto the distal roll shaft 1040. The distal roll output gear 1068, thedistal roll transfer gear 1070 and the distal roll input gear 1072 arereferred to herein as the “distal roll gear train”, generally designatedas 1069. The distal roll transfer gear 1070 is “free-wheeling” on thepivot shaft 1051 such that rotation of the distal roll shaft 1040ultimately results in the rotation of the of the distal roll pinion gear1064 without rotating the pivot shaft 1051. Rotation of the distal rollpinion gear 1064 within the ring gear 1062 results in the rotation ofthe mounting hub 1060 about the shaft axis A-A. In various forms, an endeffector or surgical implement may be directly coupled to the mountinghub 1060 such that rotation of the mounting hub 1060 results in rotationof the end effector/implement. For example, the mounting hub 1060 may beformed with a hub socket 1061 that is sized to retainingly receive aportion of the end effector/implement therein. In alternativearrangements, the mounting hub 1060 may comprise an integral part of theend effector or the end effector may be attached to the mounting hub1060 by other fastener arrangements. For example, the mounting hub 1060may be attached to a coupling assembly of the type and constructiondescribed above and then the end effector/implement may be detachablyattached to the coupling assembly.

The articulation joint 1000 may also facilitate transfer of a rotarycontrol motion through the joint 1000 to the end effector/implementattached thereto. As can be seen in FIGS. 52 and 53, a distal end of theproximal firing shaft 1030 is rotatably supported by the distal end wall1022 of the proximal clevis assembly 1020 and has an input firing gear1080 attached thereto. The input firing gear 1080 is in meshingengagement with a firing transfer gear 1082 that is journaled on thepivot shaft 1051. The firing transfer gear 1082 is in meshing engagementwith a firing output gear 1084 that is mounted on a firing output shaft1090 that is mounted in the end wall 1053 of the distal clevis 1050. Thefiring output shaft 1090 may be configured for driving engagement with acorresponding drive member or shaft on the end effector/implement. Forexample, the distal end 1092 of the firing output shaft 1090 may beformed with a hexagonal shape so that it may be received in acorresponding hexagonal socket formed in a mounting flange 1094 that maybe configured to be attached to the drive shaft of the endeffector/implement. The firing input gear 1080, the firing transfer gear1082, and the firing output gear 1084 are referred to herein as the“firing shaft gear train”, generally designated as 1081. The firingtransfer gear 1082 is “free-wheeling” on the pivot shaft 1051 such thatrotation of the proximal firing shaft 1030 ultimately results in therotation of the of the firing output shaft 1090 without rotating thepivot shaft 1051. The distal roll gear train 1069 and the firing shaftgear train 1081 are essentially “nested” together facilitatearticulation of the end effector/implement relative to the elongateshaft assembly while facilitating the transfer of rotary control motionsto the end effector and while facilitating the rotation of the endeffector about the shaft axis A-A.

FIGS. 54-60 illustrate another alternative articulation jointarrangement 1100. In at least one form, the articulation joint 1100 mayinclude a proximal clevis 1110, a central clevis 1130 and a distalclevis 1150. The articulation joint 1100 may be configured to facilitatethe articulation of an end effector or surgical implement coupledthereto about two different articulation axes B-B and C-C that aresubstantially transverse to each other as well as to the shaft axis A-Aof an elongate shaft assembly 30″ to which it is attached. For example,the articulation joint 1100 may be configured such that the centralclevis 1130 may be pivoted about the first articulation axis B-Brelative to the first clevis 1110 and the distal clevis 1150 may beselectively pivoted about a second articulation axis C-C relative to thecentral clevis 1130. The articulation joint 1100 may also facilitatesuch articulation of the end effector or surgical implement while alsoproviding a rotary control motion to the end effector/implement foractuation or manipulation thereof.

The articulation joint 1100 may be coupled to an elongate shaft assemblythat is similar in construction to the elongate shaft assembly 30described above or it may be coupled to other suitable shaft assemblies.In one arrangement, the proximal clevis 1110 is integrally formed withthe outer tube of the elongate shaft assembly 30″. As can be seen inFIGS. 54-60, the proximal clevis 1110 has an upper proximal clevis arm1112 and a lower proximal clevis arm 1114. The central clevis 1130 alsohas an upper central clevis arm 1132 and a lower central clevis arm1134. The upper proximal clevis arm is pivotally coupled to the uppercentral clevis arm 1132 by a proximal pivot pin 1116. The proximal pivotpin 1116 also pivotally couples the lower proximal clevis arm 1114 tothe lower central clevis arm 1134. The proximal pivot pin 1116 serves todefine the first articulation axis B-B.

Also in at least one arrangement, the central clevis 1130 has a rightcentral clevis arm 1136 and a left central clevis arm 1138. The distalclevis 1150 has a right distal clevis arm 1152 and a left distal clevisarm 1154. The right central clevis arm 1136 is pivotally coupled to theright distal clevis arm 1152 by a distal pivot pin 1156. The leftcentral clevis arm 1138 is pivotally coupled to the left distal clevisarm 1154 by the distal pivot pin 1156. The distal pivot pin 1156 definesthe second articulation axis C-C. In one arrangement, the distal pivotpin 1156 is non-pivotally attached to the right and left distal clevisarms 1152, 1154 such that the distal pivot pin 1156 rotates with thedistal clevis 1150 relative to the central clevis 1130.

The elongate shaft assembly 30″ may be coupled to a handle assembly thathouses a plurality of motors. One motor may be used to apply controlmotions to a first flexible cable member 1170 that extends through theelongate shaft assembly 30″ and which is operably coupled to thearticulation joint 1100. For example, the first flexible cable 1170 maybe attached to a first sheave or pulley assembly that is operablyattached to or communicates with the shaft of a corresponding motor suchthat operation of the motor causes the first cable 1170 to be actuated.

In one arrangement, the first flexible cable 1170 may be employed toselectively pivot the central clevis 1130 relative to the proximalclevis 1110 about the first articulation axis B-B. In such arrangement,for example, the first cable 1170 extends around a first pulley orsheave 1180 that is attached to the central clevis 1130. For example,the first pulley 1180 is attached to the upper central clevis arm 1132and pivotally journaled on the proximal pivot pin 1116. Actuation of thefirst cable 1170 will cause the central clevis 1130 to pivot relative tothe proximal clevis 1110 about the first articulation axis B-B.

The articulation joint 1100 may also employ a second flexible cable 1190that is received on a sheave or pulley assembly that is operablyattached to or communicates with the shaft of a corresponding motorwithin the handle assembly such that operation of the motor causes thesecond cable 1190 to be actuated. The second cable 1190 may be employedto selectively pivot the distal clevis 1150 relative to the centralclevis 1130 about the second articulation axis C-C. In such arrangement,for example, the second cable 1190 extends around a second pulley orsheave 1158 that is non-rotatably attached to the distal pivot pin 1156.Actuation of the second cable 1190 will result in the rotation of thedistal pivot pin 1156 and the distal clevis 1150 attached thereto aboutthe second articulation axis C-C relative to the central clevis 1130.

The articulation joint 1100 may also facilitate transfer of a rotarycontrol motion through the joint 1100 to the end effector/implementattached thereto. A proximal rotary firing shaft 1200 may extend throughthe elongate shaft assembly 30″ and be operably coupled to a firingmotor in the handle assembly for applying a rotary firing motionthereto. In one arrangement, the proximal firing shaft 1200 may behollow such that the second cable 1190 may extend therethrough. Theproximal firing shaft 1200 may operably interface with a proximal firinggear train 1210 operably supported in the articulation joint 1100. Forexample, in one arrangement, the first firing gear train 1210 mayinclude a proximal input firing gear 1212 that is attached to theproximal firing shaft 1200. The proximal input firing gear 1212 isoriented in meshing engagement with a proximal firing transfer gear 1214that is journaled on the proximal pivot shaft 1116 such that it canfreely rotate thereon. The proximal firing transfer gear 1212 isoriented in meshing engagement with a proximal firing output gear 1216that is coupled to a central firing shaft 1218 that rotatably passesthrough a central web 1131 of the central clevis 1130.

The articulation joint 1100 may further include a distal firing geartrain 1220 that cooperates with the proximal firing gear train 1210 totransfer the rotary firing or control motion through the articulationjoint 1100. The distal firing gear train 1220 may include a distalfiring input gear 1222 that is mounted to the central firing shaft 1216.The distal firing input gear 1222 is in meshing engagement with a distalfiring transfer gear 1224 that is rotatably mounted to the distal pivotpin 1156 such that it may freely rotate thereon. The distal firingtransfer gear 1224 is in meshing engagement with a distal firing outputgear 1226 that is rotatably supported within the distal clevis 1150. Thedistal firing output gear 1226 may be configured for driving engagementwith a corresponding drive member or shaft on the endeffector/implement.

Another form of articulation joint 1300 is shown in FIGS. 61-66. Sucharticulation joint 1300 can facilitate the articulation and rotation ofan end effector or surgical implement coupled thereto relative to theshaft axis A-A of the elongate shaft to which the articulation joint1300 is attached. The articulation joint may also facilitate suchmovement of the end effector or surgical implement while also providinga rotary control motion to the end effector/implement for actuation ormanipulation thereof. The articulation joint 1300 may be coupled to anelongate shaft assembly that is similar in construction to the elongateshaft assembly 30 described above or it may be coupled to other suitableshaft assemblies. The elongate shaft assembly may be coupled to a handleassembly that houses a plurality of motors. One motor may be used toapply control motions to a flexible cable 1310 that extends through theelongate shaft assembly and which is operably coupled to thearticulation joint 1300. For example, the flexible cable 1310 may beattached to a sheave or pulley assembly that is operably attached to orcommunicates with the shaft of a corresponding motor such that operationof the motor causes the cable 1310 to be actuated. The handle assemblymay also include a firing motor that is operably attached to a proximalfiring shaft 1330 that extends through the elongate shaft assembly tointerface with the articulation joint 1300 as will be discussed infurther detail below. The handle assembly may also include a motor thatoperably interfaces with a flexible distal roll shaft 1340 thattransmits a rotary control motion to the articulation joint 1300 whichmay be used to rotate the end effector or surgical implement about theshaft axis A-A relative to the elongate shaft. The handle assembly mayalso include a proximal roll motor that is employed to rotate theelongate shaft assembly about the shaft axis A-A in the manner describedabove.

In at least one form, the articulation joint 1300 may include a proximalclevis assembly 1320 that is attached to or formed on the end of theelongate shaft assembly. In the arrangement shown in FIGS. 61-66, theproximal clevis assembly 1320 is formed on a distal end of an outer tubeforming a portion of the elongate shaft assembly 30″. As can be seen inthose Figures, the proximal clevis assembly 1320 has a distal end wall1322 and a pair of spaced clevis arms 1324, 1326. The proximal clevis1320 is configured to be pivotally coupled to a distal clevis 1350 by anupper pivot shaft 1351 and a lower pivot shaft 1353 which serve todefine articulation axis B-B. Articulation axis B-B is substantiallytransverse to shaft axis A-A.

The distal clevis 1350 has a socket 1352 formed thereon and a pair ofdistal clevis arms 1354, 1356. The upper pivot shaft 1351 extendscentrally through the clevis arms 1324 and 1354. The lower pivot shaft1353 extends through the clevis arms 1356, and 1026 as shown in FIG. 64.The clevis arm 1356 further has a cable pulley 1358 formed thereon orattached thereto. The flexible cable 1310 is attached to the cablepulley 1358 such that actuation of the cable 1310 will result inarticulation of the distal clevis 1350 about the articulation axis B-Brelative to the proximal clevis 1320.

In various forms, the articulation joint 1300 may further include arotatable mounting hub 1360 that is rotatably received within the socket1052. The mounting hub 1060 may have a driven gear 1362 attached theretothat is adapted for meshing engagement with a distal roll pinion gear1364. The distal roll pinion gear 1364 is attached to a pinion shaft1366 that is rotatably supported in an end wall 1355 of the distalclevis 1350. In at least one arrangement, the distal roll pinion gear1364 is operated by the flexible distal roll shaft 1340 that extendsthrough a proximal support shaft 1342 extending through the elongateshaft assembly 30″. In various forms, an end effector or surgicalimplement may be directly coupled to the mounting hub 1360 such thatrotation of the mounting hub 1360 results in rotation of the endeffector/implement. For example, the mounting hub 1360 may be formedwith a hub socket 1361 that is sized to retainingly receive a portion ofthe end effector/implement therein. In alternative arrangements, themounting hub 1360 may comprise an integral part of the end effector orthe end effector may be attached to the mounting hub 1360 by otherfastener arrangements. For example, the mounting hub 1360 may beattached to a coupling assembly of the type and construction describedabove and then the end effector/implement may be detachably attached tothe coupling assembly.

The articulation joint 1300 may also facilitate transfer of a rotarycontrol motion through the joint 1300 to the end effector/implementattached thereto. As can be seen in FIGS. 63 and 64, a distal end of theproximal firing shaft 1330 is rotatably supported by the distal end wall1322 of the proximal clevis assembly 1320 and has a firing input gear1380 attached thereto. The input firing gear 1380 is in meshingengagement with a firing transfer gear 1382 that is journaled on thelower pivot shaft 1353. The firing transfer gear 1382 is in meshingengagement with a firing output gear 1384 that is mounted on a firingoutput shaft 1390 that extends through the end wall 1355 of the distalclevis 1350 and the end wall 1370 of the mounting hub 1360. The firingoutput shaft 1390 may be configured for driving engagement with acorresponding drive member or shaft on the end effector/implement. Forexample, the distal end 1392 of the firing output shaft 1390 may beformed with a hexagonal shape so that it may be received in acorresponding hexagonal socket formed in a mounting flange 1394 that maybe configured to be attached to the drive shaft of the endeffector/implement. The firing input gear 1380, the firing transfer gear1382, and the firing output gear 1384 are referred to herein as thefiring shaft gear train, generally designated as 1381. The firingtransfer gear 1382 is “free-wheeling” on the lower pivot shaft 1353 suchthat rotation of the proximal firing shaft 1330 ultimately results inthe rotation of the of the firing output shaft 1390 without rotating thelower pivot shaft 1353. The distal roll gear train 1369 and the firingshaft gear train 1381 facilitate articulation of the endeffector/implement relative to the elongate shaft assembly whilefacilitating the transfer of rotary control motions to the end effectorand while facilitating the rotation of the end effector about the shaftaxis A-A.

Alternative Motor Mounting Assemblies

FIGS. 67-69 illustrate an alternative motor mounting assembly generallydesignated as 1750. The motor mounting assembly 1750 may be supportedwithin handle housing segments 23 and 24 that are couplable together bysnap features, screws, etc. and serve to form a pistol grip portion 26of the handle assembly 20. In at least one form, the motor mountingassembly 1750 may comprise a motor housing 1752 that is removablysupported within the handle housing segments 23 and 24. In at least oneform, for example, the motor housing 1752 has a motor bulkhead assembly1756 attached thereto. The motor housing 1752 serves to support motors402, 530, 560 and 610. Each motor has its own circuit control board 1780attached thereto for controlling the operation of each motor in thevarious manner described herein.

In some forms, the implement portion 100 may comprise an electrosurgicalend effector that utilizes electrical energy to treat tissue. Exampleelectrosurgical end effectors and associated instruments are describedin U.S. patent application Ser. No. 13/536,393, entitled “Surgical EndEffector Jaw and Electrode Configurations,” Attorney Docket No.END7137USNP/120141 and U.S. patent application Ser. No. 13/536,417,entitled “Electrode Connections for Rotary Drive Surgical Tools,”Attorney Docket No. END7149USNP/120153, both of which are incorporatedby reference herein in their entireties. FIGS. 70-73 illustrate anexample end effector 3156 making up an alternate implement portion 100.The end effector 3156 may be adapted for capturing and transectingtissue and for the contemporaneously welding the captured tissue withcontrolled application of energy (e.g., radio frequency (RF) energy).The first jaw 3160A and the second jaw 3160B may close to therebycapture or engage tissue about a longitudinal axis 3194 defined by anaxially moveable member 3182. The first jaw 3160A and second jaw 3160Bmay also apply compression to the tissue.

FIG. 70 shows a perspective view of some forms of an electrosurgical endeffector 3156 for use with the surgical instrument 10. FIG. 70 shows theend effector 3156 with the jaws 3160A, 3160B open. FIG. 71 shows aperspective view of some forms of the end effector 3156 with the jaws3160A, 3160B closed. As noted above, the end effector 3156 may comprisethe upper first jaw 3160A and the lower second jaw 3160B, which may bestraight or curved. The first jaw 3160A and the second jaw 3160B mayeach comprise an elongate slot or channel 3162A and 3162B (FIG. 70),respectively, disposed outwardly along their respective middle portions.Further, the first jaw 3160A and second jaw 3160B may each havetissue-gripping elements, such as teeth 3198, disposed on the innerportions of first jaw 3160A and second jaw 3160B. The first jaw 3160Amay comprise an upper first jaw body 3200A with an upper firstoutward-facing surface 3202A and an upper first energy delivery surface3204A. The second jaw 3160B may comprise a lower second jaw body 3200Bwith a lower second outward-facing surface 3202B and a lower secondenergy delivery surface 3204B. The first energy delivery surface 3204Aand the second energy delivery surface 3204B may both extend in a “U”shape about the distal end of the end effector 3156. It will beappreciated that the end effector 3156 may be rotatable andarticulatable in a manner similar to that described herein with respectto the end effector 102.

FIG. 72 shows one form of an axially movable member 3182 of the endeffector 3156. The axially movable member 3182 is driven by a threadeddrive shaft 3151. (FIG. 70) A proximal end of the threaded drive shaft3151 may be configured to be non-rotatably coupled to the output socket238 and thereby receive rotational motion provided by the motor 530. Theaxially movable member 3182 may comprise a threaded nut 3153 forreceiving the threaded drive shaft 3151 such that rotation of thethreaded drive shaft 3151 causes the axially movable member 3182 totranslate distally and proximally along the axis 3194. (FIG. 72) Theaxially moveable member 3182 may comprise one or several pieces, but inany event, may be movable or translatable with respect to the elongateshaft 158 and/or the jaws 3160A, 3160B. Also, in at least some forms,the axially moveable member 3182 may be made of 17-4 precipitationhardened stainless steel. The distal end of axially moveable member 3182may comprise a flanged “I”-beam configured to slide within the channels3162A and 3162B in jaws 3160A and 3160B. The axially moveable member3182 may slide within the channels 3162A, 3162B to open and close firstjaw 3160A and second jaw 3160B. The distal end of the axially moveablemember 3182 may also comprise an upper flange or “c”-shaped portion3182A and a lower flange or “c”-shaped portion 3182B. The flanges 3182Aand 3182B respectively define inner cam surfaces 3206A and 3206B forengaging outward facing surfaces of first jaw 3160A and second jaw3160B. The opening-closing of jaws 3160A and 3160B can apply very highcompressive forces on tissue using cam mechanisms which may includemovable “I-beam” axially moveable member 3182 and the outward facingsurfaces 3208A, 3208B of jaws 3160A, 3160B.

More specifically, referring now to FIGS. 70-72, collectively, the innercam surfaces 3206A and 3206B of the distal end of axially moveablemember 3182 may be adapted to slidably engage the first outward-facingsurface 3208A and the second outward-facing surface 3208B of the firstjaw 3160A and the second jaw 3160B, respectively. The channel 3162Awithin first jaw 3160A and the channel 3162B within the second jaw 3160Bmay be sized and configured to accommodate the movement of the axiallymoveable member 3182, which may comprise a tissue-cutting element 3210,for example, comprising a sharp distal edge. FIG. 71, for example, showsthe distal end of the axially moveable member 3182 advanced at leastpartially through channels 3162A and 3162B (FIG. 70). The advancement ofthe axially moveable member 3182 may close the end effector 3156 fromthe open configuration shown in FIG. 70. In the closed position shown byFIG. 71, the upper first jaw 3160A and lower second jaw 3160B define agap or dimension D between the first energy delivery surface 3204A andsecond energy delivery surface 3204B of first jaw 3160A and second jaw3160B, respectively. In various forms, dimension D can equal from about0.0005″ to about 0.040″, for example, and in some forms, between about0.001″ to about 0.010″, for example. Also, the edges of the first energydelivery surface 3204A and the second energy delivery surface 3204B maybe rounded to prevent the dissection of tissue.

FIG. 73 is a section view of some forms of the end effector 3156. Theengagement, or tissue-contacting, surface 3204B of the lower jaw 3160Bis adapted to deliver energy to tissue, at least in part, through aconductive-resistive matrix, such as a variable resistive positivetemperature coefficient (PTC) body. At least one of the upper and lowerjaws 3160A, 3160B may carry at least one electrode 3212 configured todeliver the energy from a generator 3164 to the captured tissue. Theengagement, or tissue-contacting, surface 3204A of upper jaw 3160A maycarry a similar conductive-resistive matrix (e.g., a PTC material), orin some forms the surface may be a conductive electrode or an insulativelayer, for example. Alternatively, the engagement surfaces of the jawscan carry any of the energy delivery components disclosed in U.S. Pat.No. 6,773,409, filed Oct. 22, 2001, entitled ELECTROSURGICAL JAWSTRUCTURE FOR CONTROLLED ENERGY DELIVERY, the entire disclosure of whichis incorporated herein by reference.

The first energy delivery surface 3204A and the second energy deliverysurface 3204B may each be in electrical communication with the generator3164. The generator 3164 is connected to the end effector 3156 via asuitable transmission medium such as conductors 3172, 3174. In someforms, the generator 3164 is coupled to a controller, such as a controlunit 3168, for example. In various forms, the control unit 3168 may beformed integrally with the generator 3164 or may be provided as aseparate circuit module or device electrically coupled to the generator3164 (shown in phantom to illustrate this option). The generator 3164may be implemented as an external piece of equipment and/or may beimplemented integral to the surgical instrument 10.

The first energy delivery surface 3204A and the second energy deliverysurface 3204B may be configured to contact tissue and deliverelectrosurgical energy to captured tissue which are adapted to seal orweld the tissue. The control unit 3168 regulates the electrical energydelivered by electrical generator 3164 which in turn deliverselectrosurgical energy to the first energy delivery surface 3204A andthe second energy delivery surface 3204B. The control unit 3168 mayregulate the power generated by the generator 3164 during activation.

As mentioned above, the electrosurgical energy delivered by electricalgenerator 3164 and regulated, or otherwise controlled, by the controlunit 3168 may comprise radio frequency (RF) energy, or other suitableforms of electrical energy. Further, the opposing first and secondenergy delivery surfaces 3204A and 3204B may carry variable resistivepositive temperature coefficient (PTC) bodies that are in electricalcommunication with the generator 3164 and the control unit 3168.Additional details regarding electrosurgical end effectors, jaw closingmechanisms, and electrosurgical energy-delivery surfaces are describedin the following U.S. patents and published patent applications: U.S.Pat. Nos. 7,087,054; 7,083,619; 7,070,597; 7,041,102; 7,011,657;6,929,644; 6,926,716; 6,913,579; 6,905,497; 6,802,843; 6,770,072;6,656,177; 6,533,784; and 6,500,176; and U.S. Pat. App. Pub. Nos.2010/0036370 and 2009/0076506, all of which are incorporated herein intheir entirety by reference and made a part of this specification.

A suitable generator 3164 is available as model number GEN11, fromEthicon Endo-Surgery, Inc., Cincinnati, Ohio. Also, in some forms, thegenerator 3164 may be implemented as an electrosurgery unit (ESU)capable of supplying power sufficient to perform bipolar electrosurgeryusing radio frequency (RF) energy. In some forms, the ESU can be abipolar ERBE ICC 350 sold by ERBE USA, Inc. of Marietta, Ga. In someforms, such as for bipolar electrosurgery applications, a surgicalinstrument having an active electrode and a return electrode can beutilized, wherein the active electrode and the return electrode can bepositioned against, adjacent to and/or in electrical communication with,the tissue to be treated such that current can flow from the activeelectrode, through the positive temperature coefficient (PTC) bodies andto the return electrode through the tissue. Thus, in various forms, thesurgical instrument 10 utilizing the end effector 3156 creates a supplypath and a return path, wherein the captured tissue being treatedcompletes, or closes, the circuit. In some forms, the generator 3164 maybe a monopolar RF ESU and the surgical instrument 10 may utilizecomprise a monopolar end effector in which one or more active electrodesare integrated. For such a system, the generator 3164 may utilize areturn pad in intimate contact with the patient at a location remotefrom the operative site and/or other suitable return path. The returnpad may be connected via a cable to the generator 3164.

During operation of electrosurgical instrument 150, the user generallygrasps tissue, supplies energy to the captured tissue to form a weld ora seal, and then drives a tissue-cutting element 3210 at the distal endof the axially moveable member 3182 through the captured tissue.According to various forms, the translation of the axial movement of theaxially moveable member 3182 may be paced, or otherwise controlled, toaid in driving the axially moveable member 3182 at a suitable rate oftravel. By controlling the rate of the travel, the likelihood that thecaptured tissue has been properly and functionally sealed prior totransection with the cutting element 3210 is increased.

In some forms, the implement portion 100 may comprise an ultrasonic endeffector that utilizes harmonic or ultrasonic energy to treat tissue.FIG. 74 illustrates one form of an ultrasonic end effector 3026 for usewith the surgical instrument 10. The end effector assembly 3026comprises a clamp arm assembly 3064 and a blade 3066 to form the jaws ofthe clamping mechanism. The blade 3066 may be an ultrasonicallyactuatable blade acoustically coupled to an ultrasonic transducer 3016positioned within the end effector 3026. Examples of small sizedtransducers and end effectors comprising transducers are provided inco-pending U.S. application Ser. No. 13/538,601, entitled UltrasonicSurgical Instruments with Distally Positioned Transducers and U.S.Application Publication No. 2009/0036912. The transducer 3016 may beacoustically coupled (e.g., directly or indirectly mechanically coupled)to the blade 3066 via a waveguide 3078.

A tubular actuating member 3058 may move the clamp arm assembly 3064 toan open position in direction 3062A wherein the clamp arm assembly 3064and the blade 3066 are disposed in spaced relation relative to oneanother and to a clamped or closed position in direction 3062B whereinthe clamp arm assembly 3064 and the blade 3066 cooperate to grasp tissuetherebetween. The distal end of the tubular reciprocating tubularactuating member 3058 is mechanically engaged to the end effectorassembly 3026. In the illustrated form, the distal end of the tubularreciprocating tubular actuating member 3058 is mechanically engaged tothe clamp arm assembly 3064, which is pivotable about the pivot point3070, to open and close the clamp arm assembly 3064. For example, in theillustrated form, the clamp arm assembly 3064 is movable from an openposition to a closed position in direction 3062B about a pivot point3070 when the reciprocating tubular actuating member 3058 is retractedproximally. The clamp arm assembly 3064 is movable from a closedposition to an open position in direction 3062A about the pivot point3070 when the reciprocating tubular actuating member 3058 is translateddistally. (FIG. 75)

The tubular actuating member 3058 may be translated proximally anddistally due to rotation of a threaded drive shaft 3001. A proximal endof the threaded drive shaft 3001 may be configured to be non-rotatablycoupled to the output socket 238 and thereby receive rotational motionprovided by the motor 530. The tubular actuating member 3058 maycomprise a threaded nut 3059 for receiving the threaded drive shaft 3001such that rotation of the threaded drive shaft 3001 causes the tubularactuating member 3058 to translate distally and proximally. FIGS. 76-77show additional view of one form of the axially movable member 3058 andtubular nut 3059. In some forms, the tubular actuating member 3058defines a cavity 3003. The waveguide 3078 and/or a portion of the blade3066 may extend through the cavity 3003, as illustrated in FIG. 74.

In one example form, the distal end of the ultrasonic transmissionwaveguide 3078 may be coupled to the proximal end of the blade 3066 byan internal threaded connection, preferably at or near an antinode. Itis contemplated that the blade 3066 may be attached to the ultrasonictransmission waveguide 3078 by any suitable means, such as a weldedjoint or the like. Although the blade 3066 may be detachable from theultrasonic transmission waveguide 3078, it is also contemplated that thesingle element end effector (e.g., the blade 3066) and the ultrasonictransmission waveguide 3078 may be formed as a single unitary piece.

The ultrasonic transducer 3016, which is known as a “Langevin stack”,generally oscillates in response to an electric signal provided by agenerator 3005 (FIG. 74). For example, the transducer 3016 may comprisea plurality of piezoelectric elements or other elements for convertingan electrical signal from the generator 3005 to mechanical energy thatresults in primarily a standing acoustic wave of longitudinal vibratorymotion of the ultrasonic transducer 3016 and the blade 3066 portion ofthe end effector assembly 3026 at ultrasonic frequencies. The ultrasonictransducer 3016 may, but need not, have a length equal to an integralnumber of one-half system wavelengths (nλ/2; where “n” is any positiveinteger; e.g., n=1, 2, 3 . . . ) in length. A suitable vibrationalfrequency range for the transducer 3016 and blade 3066 may be about 20Hz to 32 kHz and a well-suited vibrational frequency range may be about30-10 kHz. A suitable operational vibrational frequency may beapproximately 55.5 kHz, for example.

The generator 3005 may be any suitable type of generator locatedinternal to or external from the surgical instrument 10. A suitablegenerator is available as model number GEN11, from Ethicon Endo-Surgery,Inc., Cincinnati, Ohio. When the transducer 3016 is energized, avibratory motion standing wave is generated through the waveguide 3078and blade 3066. The end effector 3026 is designed to operate at aresonance such that an acoustic standing wave pattern of predeterminedamplitude is produced. The amplitude of the vibratory motion at anypoint along the transducer 3016, waveguide 3078 and blade 3066 dependsupon the location along those components at which the vibratory motionis measured. A minimum or zero crossing in the vibratory motion standingwave is generally referred to as a node (i.e., where motion is minimal),and a local absolute value maximum or peak in the standing wave isgenerally referred to as an anti-node (e.g., where local motion ismaximal). The distance between an anti-node and its nearest node isone-quarter wavelength (λ/4).

In one example form, the blade 3066 may have a length substantiallyequal to an integral multiple of one-half system wavelengths (nλ/2). Adistal end of the blade 3066 may be disposed near an antinode in orderto provide the maximum longitudinal excursion of the distal end. Whenthe transducer assembly is energized, the distal end of the blade 3066may be configured to move in the range of, for example, approximately 10to 500 microns peak-to-peak, and preferably in the range of about 30 to64 microns at a predetermined vibrational frequency of 55 kHz, forexample.

In one example form, the blade 3066 may be coupled to the ultrasonictransmission waveguide 3078. The blade 3066 and the ultrasonictransmission waveguide 3078 as illustrated are formed as a single unitconstruction from a material suitable for transmission of ultrasonicenergy. Examples of such materials include Ti6Al4V (an alloy of Titaniumincluding Aluminum and Vanadium), Aluminum, Stainless Steel, or othersuitable materials. Alternately, the blade 3066 may be separable (and ofdiffering composition) from the ultrasonic transmission waveguide 3078,and coupled by, for example, a stud, weld, glue, quick connect, or othersuitable known methods. The length of the ultrasonic transmissionwaveguide 3078 may be substantially equal to an integral number ofone-half wavelengths (nλ/2), for example. The ultrasonic transmissionwaveguide 3078 may be preferably fabricated from a solid core shaftconstructed out of material suitable to propagate ultrasonic energyefficiently, such as the titanium alloy discussed above (i.e., Ti6Al4V)or any suitable aluminum alloy, or other alloys, for example.

In some forms, the surgical instrument 10 may also be utilized withother stapler-type end effectors. For example, FIG. 78 illustrates oneform of a linear staple end effector 3500 that may be used with thesurgical instrument 10. The end effector 3500 comprises an anvil portion3502 and a translatable staple channel 3514. The translatable staplechannel 3514 is translatable in the distal and proximal directions, asindicated by arrow 3516. A threaded drive shaft 3506 may be coupled tothe output socket 238, for example, as described herein above to receiverotational motion provided by the motor 530. The threaded drive shaft3506 may be coupled to a threaded nut 3508 fixedly coupled to the staplechannel 3514 such that rotation of the threaded drive shaft 3506 causestranslation of the staple channel 3514 in the directions indicated byarrow 3516. The nut 3508 may also be coupled to a driver 3510, whichmay, in turn, contact a staple cartridge 3512. As it translatesdistally, the driver 3510 may push staples from the staple cartridge3512 against the anvil 3502, thus driving the staples through any tissuepositioned between the staple channel 3514 and the anvil 3502.

Also, in some forms, the surgical instrument may be utilized with acircular staple end effector. FIG. 79 illustrates one form of a circularstaple end effector 3520 that may be used with the surgical instrument10. The end effector 3520 comprises an anvil 3522 and a staple portion3524. A threaded drive shaft 3530 extends from the anvil 3522 throughthe staple portion 3524. The threaded drive shaft 3530 may be coupled tothe output socket 238, for example, as described herein above to receiverotational motion provided by the motor 530. A threaded nut 3532 may becoupled to the staple portion 3524 such that rotation of the threadeddrive shaft 3530 alternately translates the staple portion 3524 distallyand proximally as indicated by arrow 3534. The threaded shaft may alsobe coupled to a driver 3528 such that distal motion of the stapleportion 3524 pushes the driver 3528 distally into a staple cartridge3526 to drive staples from the cartridge 3526 into any tissue positionedbetween the anvil 3522 and the staple portion 3524. In some embodiments,the end effector 3520 may also comprise a knife or cutting implement3535 for cutting tissue prior to stapling.

In addition to different end effectors, it will be appreciated thatother implement portions may be interchangeable with respect to thesurgical instrument 10. For example, some forms of the surgicalinstrument 10 utilize different power cords. FIG. A illustrates severalexample power cords 3540, 3542, 3544 for use with the surgicalinstrument. Each of the power cords 3540, 3542, 3544 comprises a socket3546 for coupling to the surgical instrument 10. The power cords 3540,3542, 3544 may be utilized to connect the surgical instrument 10 tovarious power sources. For example power cords 3540 and 3542 comprisesockets 3550, 3552 to be received by generators, such as the modelnumber GEN11 generator, from Ethicon Endo-Surgery, Inc., in Cincinnati,Ohio. Such a generator may provide power to the instrument 10 and/or mayprovide a signal to drive an electrosurgical and/or ultrasonic endeffector. Power cord 3544 comprises a plug 3548 that may be plugged intoa wall socket to provide power to the instrument 10 (e.g., in lieu ofthe battery 802).

In some forms, the surgical instrument may also comprise interchangeableimplement portions that include different shafts. FIG. 81 illustratesseveral example shafts 3554, 3556, 3558 that can be used with thesurgical instrument 10. Each shaft 3554, 3556, 3558 comprises adetachable drive mount portion 700′, 700″, 700′″ similar to thedetachable drive mount portion 700 that may be received by theinstrument 10 as described herein above. Each shaft 3554, 3556, 3558also comprises a coupler assembly 3557 for receiving an end effectorsimilar to the coupler assembly 200 described herein above. In someembodiments, different shafts are configured to receive different typesof end effectors at the coupler assembly 3557. The shafts 3554, 3556,3558 may each comprise different characteristics including, for example,different lengths, the presence or absence of articulation, passive oractive articulation, different degrees of articulation, differentdiameters, different curvatures, etc. For example, the shaft 3554defines a curve 3559 off the center axis of the shaft. The shaft 3558defines an articulation joint 3560 that may be articulated in a mannersimilar to that described herein above with respect to the articulationjoint 310.

It will be appreciated that different kinds of implement portions 100(e.g., power cords, shafts, end effectors, etc.) require the variousmotors and other components of the surgical instrument 10 to operate indifferent ways. For example, powered end effectors, such as theelectrosurgical end effector 3156 and ultrasonic end effector 3026,require an energy signal for powering electrodes and/or ultrasonicblades. Different end effectors may also require different motion of thevarious motors 402, 560, 530, 610 for actuation, including, for example,the actuation of different motors, the provision of different amounts oftorque, etc. In various forms, the implement portions 100 may providethe surgical instrument 10 with control parameters.

FIG. 82 is a block diagram of the handle assembly 20 of the surgicalinstrument 10 showing various control elements. The control elementsshown in FIG. 82 are configured to receive control parameters fromvarious implement portions and control the surgical instrument 10 basedon the received control parameters and based on one or more inputcontrol signals received from the clinician (e.g., via the joystickcontrol 840 or other suitable actuation device). The control elementsmay comprise a control circuit 3702 for controlling the surgicalinstrument 10. In various forms, the control circuit 3702 may execute acontrol algorithm for operating the surgical instrument 10 including anyinstalled implement portions. In some forms, the control circuit 3702 isimplemented on the proximal circuit board 820 described herein above.The control circuit 3702 comprises a microprocessor 3706 and associatedmemory and/or data storage 3708. In some forms the control circuit 3702may also comprise a generator circuit 3704 for providing a power signalto an ultrasonic and/or electrosurgical device. The generator circuit3704 may operate as a stand-alone component or in conjunction with anexternal generator.

FIG. 82 also shows motors 3714, which may correspond to the motors 402,560, 530, 610 described above. A battery 3713 may correspond to thebattery 802 described herein above. Input to the control circuit 3702may be provided by the joystick control 840 or other suitable actuationdevice. The various surgical implement portions 100 described herein maybe coupled to the handle 20 at respective sockets 3710, 3712. The socket3712 may receive a shaft, such as the shafts 3554, 3556, 3558. Forexample, the socket 3712 may receive a shaft in a manner similar to theway that the handle 20 receives the detachable derive mount 700 asdescribed herein above. The socket 3710 may be configured to receive acord socket, such as the sockets 3546 described herein above.

The control circuit 3702, in conjunction with various other controlelements such as the sockets 3710, 3712, may receive control parametersfrom various installed implement portions. Control parameters maycomprise, for example, data describing properties of the implementportions, data describing algorithms for operating the instrument 10with the implement portions installed, etc. Sockets 3710, 3712 maymechanically and communicatively couple to the various implementportions. For example, various implement portions may comprise circuits3720 for storing control parameters. Such circuits 3720 are shown inconjunction with the power cords 3540, 3542, 3544 in FIG. 80 and inconjunction with the shafts 3554, 3556 3558 of FIG. 81. Also, FIG. 83illustrates one form of various end effector implement portions 3730,3732, 3734, 3736, 3738 comprising circuits 3720 as described herein. Thecircuits 3720 may comprise one or more data storage components forstoring control parameters for provision to the control circuit 3702.Such data storage components can include any suitable type of memorydevice (e.g., electrically erasable programmable read only memory(EEPROM), digital register, any other type of memory, etc.). Memorydevices may also include coils or other hardware components configuredto modulate predetermined control parameters, for example, in responseto a radio frequency identification (RFID) interrogation signal. In someforms, the circuits 3720 make a direct wired connection to the controlcircuit 3702, for example, via respective sockets 3710, 3712.Accordingly, the control circuit 3702 may directly communicate with thevarious circuits 3720 to receive control parameters.

In some forms, the circuits 3720 comprise passive or active RFIDdevices. The handle 20 may comprise one or more antennas 3716, 3718,which may be positioned at or near the respective sockets 3710, 3712.Utilizing the antennas 3716, 3718, the control circuit 3702 mayinterrogate the circuits 3720 on installed implement portions toretrieve the control parameters. In some forms, the control circuit 3702is programmed to interrogate the various implement portions uponstart-up and/or upon an indication that an implement portion has beeninstalled and/or removed. In response the control circuit 3702 mayreceive a reflected signal from the RFID device. The reflected signalmay indicate the relevant control parameters. In some forms, thecircuits 3720 may comprise active RFID devices that transmit the datadescribing their associated implement portions, for example, uponinstallation.

As illustrated in FIG. 81, some shaft forms may comprise antennas 3719at distal portions. The antennas 3719 may be in communication with thecontrol circuit 3702 via conductors (not shown) extending through therespective shafts allowing the control circuit 3702 to interrogate RFIDdevice circuits 3720 on end effectors, such as end effectors 3730, 3732,3734, 3736, 3738. In some forms, antennas 3718 positioned in the handlemay receive and transmit sufficient power so as to interrogate an RFIDdevice circuit 3720 on an end effector without the requiring a separateantenna 379 in the shaft. In some arrangements, the circuits 3720 may beconfigured to make a wired connection to the control circuit 3702. Forexample, antennas 3716, 3718, 3719 may be omitted.

FIG. 84 is a block diagram showing one form of a control configuration3800 to be implemented by the control circuit 3702 to control thesurgical instrument 10. According to the configuration 3800, the controlcircuit 3702 is programmed with a control algorithm 3802. The controlalgorithm 3802 receives control parameters from installed implementportions in the form of input variables 3801. The input variables 3801may describe properties of installed implement portion. The controlalgorithm 3802 also receives one or more input control signals 3818(e.g., from the joystick control 840, a robotic system, or othersuitable actuation device operated by a clinician). Based on the inputvariables 3801, the control algorithm 3802 may operate the surgicalinstrument 10 by translating the one or more input control signals 3818to an output motor control signal 3814 for controlling the motors 3714and an optional output energy control signal 3816 for controlling anultrasonic and/or electrosurgical end effector. It will be appreciatedthat not all forms of the surgical instrument 10 need receive inputvariables from all of the listed implement portions. For example, someforms of the surgical instrument comprise a single shaft and/or a fixedend effector. Also, some forms of the surgical instrument (orconfigurations thereof) may omit a power cord.

The control algorithm 3802 may implement a plurality of functionalmodules 3804, 3806, 3810, 3812 related to different aspects of thesurgical instrument 10. A firing module 3804 may translate the one ormore input control signals 3818 to one or more output motor controlsignals 3814 for controlling the respective motors 3714 to fire theinstrument 10. An articulation module 3806 may translate the one or moreinput control signals 3818 to one or more output motor control signals3814 for articulating the shaft of the instrument 10. The power module3812 may route power to the various components of the surgicalinstrument 10, as required by an installed power cord. For forms of theinstrument 10 utilizing energy at the end effector (e.g., ultrasonicand/or electrosurgical instruments), an energy module 3810 may translatethe one or more input control signals 3818 into output energy signals3816 to be provided to the end effector. The energy signals 3816 may beproduced by the generator 3704 and/or by an external generator (notshown in FIG. 84) and may be provided to a transducer 3016 and/or energydelivery surfaces 3204A, 3204B at the end effector.

The various modules 3804, 3806, 3810, 3812 of the control algorithm 3802may utilize control parameters in the form of input variables 3801 totranslate the one or more input control signals 3818 into output signals3814, 3816. For example, input variables 3801 received from differentimplement portions may affect the control algorithm 3802 in differentways. Input variables 3801 received from power cord, such as 3540, 3542,3544 may include, for example, a cord type, whether the cord isconnected to an external object such as a generator or power socket, theidentity of the external object to which the cord is connected, etc. Onetype of power cord, such as cord 3544, may be configured to receivepower from an external power socket, such as a wall outlet. When thecontrol circuit 3702 determines that a cord of this type is installed(e.g., at socket 3710), the power module 3812 may be programmed toconfigured the control circuit 3702 to power the motors 3714 and/orenergy elements from power provided through the installed cordimplement. Power provided through the installed cord implement may beused in addition to or instead of power provided by the battery 3713.

Another type of cord, such as 3540 and 3542, may be configured tocommunicate with an external generator. The power module 3812 and/orenergy module 3810 may configured the control circuit 3702 to power theenergy element based on an energy signal received via the installedpower cord. In addition, the energy module 3810 may configure thecontrol circuit 3702 to provide input to the generator via the installedpower cord. Such input may include, for example, an input control signal3818 indicating that the clinician has requested energy. In some forms,the input variables 3801 received from the power cord may also indicatea type of generator that the power cords is configured to (and/or is)coupled to. Example generators may include stand-alone electrosurgicalgenerators, stand-alone ultrasonic generators, combinedelectrosurgical/ultrasonic generators, etc. In some forms, the inputvariables 3801 received from the cord may also indicate a type ofgenerator with which the cord is configured to couple. In some forms,the type of generator indicated may affect the operation of the controlalgorithm 3802. For example, different generator types may havedifferent control interfaces and expect different forms of instructionsfrom the surgical instrument 10 and/or provide outputs in differentforms.

When the shaft, such as one of shafts 3554, 3556, 3558, is a removableimplement portion, input variables 3801 received from the shaft mayindicate various properties of the shaft. Such properties may include,for example, a length of the shaft, a position and degree of curvatureof the shaft (if any), parameters describing an articulation joint ofthe shaft (if any), etc. The length of the shaft and the position anddegree of curvature of the shaft may be utilized, for example, by thefiring module 3804 and/or by the articulation module 3806 of the controlalgorithm 3802 to determine torque requirements and/or tolerances. Theparameters describing the articulation joint of the shaft may indicate,or allow the articulation module 3806 to derive, various motor motionsrequired to articulate the shaft in different directions. In someembodiments, the input variables 3801 may also indicate a degree ofallowable articulation, which the articulation module 3806 may translateinto a maximum allowable motor movement. In some forms, input variables3801 received from the shaft may also indicate whether the installedshaft supports shaft rotation and/or end effector rotation. Suchvariables 3801 may be utilized by the control algorithm 3802 to derivewhich motor or motors 3714 are to be actuated for shaft and/or endeffector rotation, the torque and number of rotations indicated for eachmotor 3714, etc.

Input variables 3801 received from end effector implement portions maybe of different forms based on the type of end effector used. Forexample, endocutters and other stapler end effectors, such as the endeffector 102 described herein above, may provide variable valuesindicating the length of the end effector (e.g., 45 mm or 60 mm stapleline), whether the anvil and elongate channel are straight or curved,the motor 3714 to which a drive shaft, such as drive shaft 180, iscoupled, etc. Such input variables 3801 may be utilized by the firingmodule 3804 to translate input control signals 3818 requesting firing ofthe instrument 10 to output motor control signals 3814. For example, thelength, curvature, etc. of the end effector may determine the motor 3714to be activated, the amount of force or torque required to be provided,the number of motor rotations required to fire, etc. Similarly, inputvariables 3818 received from linear or circular stapler end effectors,such as 3500 and 3520, may be utilized by the firing algorithm 3804 todetermine the motor 3714 to be actuated to fire, the amount of force ortorque required to be provide in response to different levels of theinput control signal 3818 related to firing, the number of motorrotations required to fire, etc.

When the end effector is an energy end effector, such as theelectrosurgical end effector 3156 or the ultrasonic end effector 3026,the received input variables 3801 may describe information relating tothe closure motion of the end effector, as well as informationdescribing the energy elements including, for example, the timing ofenergy provision in the context of the firing stroke. The informationdescribing the closure motion may be utilized, for example, by thefiring module 3804 to determine which motor or motors 3714 are to beactuated for firing and/or retraction, the torque and number ofrotations indicated for each motor 3714, etc. Information describing theenergy elements may be utilized, for example, by the energy module 3810to generate the output energy signal 3816. For example, the energymodule 3810 may determine what type of output energy signal 3816 isrequired (e.g., voltage, current, etc.), whether the signal can begenerated by an internal generator 3704, whether there are any lock-outsto be implemented with the signal. Example lock-outs may prevent thefiring motion from taking place unless energy is being provided and/ormay prevent energy from being provided unless the firing motion istaking place. In some embodiments, the energy module 3810 may alsoderive the timing of the output energy signal 3816 in the context of theinstrument's firing stroke. For example, referring to theelectrosurgical end effector 3156, the energy module 3810 may derive howlong the energy delivery surfaces 3204A, 3204B should be activatedbefore the tissue cutting element 3210 is advanced.

FIG. 85 is a flowchart showing one example form of a process flow 3600for implementing the control algorithm 3802 with the control circuit3702. At 3602, the control circuit 3702 may receive an indication of thepresence of an implement portion (e.g., a power cord, shaft, endeffector, etc.). The indication may be generated automatically uponinstallation of the implement portion. For example, in forms where theimplement portion comprises an active RFID, the indication of thepresence of the implement portion may be provided by the active RFID.Also, in some embodiments, the socket 3710, 3712 by which the implementportion is connected to the instrument 10 may comprise a switch thatindicates the presence of the implement portion. At 3604, the controlcircuit 3702 may interrogate the implement portion for input variables3801. When the implement portion comprises a passive RFID device, theinterrogation may comprise illuminating the RFID device with a radiofrequency signal. When the implement portion is in wired communicationwith control circuit, 3702, the interrogation may comprise sending arequest to a memory device associated with the implement portion.

At 3606, the control circuit 3702 may receive input variables 3801 fromthe implement portion. The input variables 3801 may be received in anysuitable manner. For example, when the implement portion comprises apassive RFID device, the input variables 3801 may be derived bydemodulating a return signal from the RFID device. When there is a wiredconnection between the implement portion and the circuit 3702, the inputvariables 3801 may be received directly from a memory device at theimplement portion, etc. At 3608, the control circuit 3702 may apply theinput variables 3801 to the control algorithm 3802, for example, asdescribed herein above. This may have the effect of configuring thepre-existing algorithm 3802 to operate the instrument 10 with whateverimplement portion or portions are installed.

FIG. 86 is a block diagram showing another form of a controlconfiguration 3900 to be implemented by the control circuit 3702 tocontrol the surgical instrument 10. In the configuration 3900, thecontrol parameters received from the various implement portions comprisealgorithms for controlling the respective implement portions. Thecontrol circuit 3702 implements a shell control algorithm 3902comprising an operating system 3904. The operating system 3904 isprogrammed to interrogate installed implement potions to receive controlparameters, in the form of implement algorithms 3906. Each implementalgorithm 3906 may describe a manner of translating input controlsignals 3908 into output motor control signals 3910 and output energysignals 3912. Upon receiving the implement algorithms 3906, theoperating system 3904 may execute the algorithms 3906 to operate theinstrument 10.

In some embodiments, the operating system 3904 may also reconcile thevarious algorithms 3906. For example, an implement algorithm 3906received from an energy end effector may take different configurationsbased on whether the instrument is in communication with an externalgenerator, or utilizing the internal generator 3704. Accordingly, theoperating system 3904 may configure an implement algorithm 3906 for anenergy end effector based on whether an implement algorithm 3906 hasbeen received from a corresponding power cord configured to couple withan external generator. Also, in some forms, the tolerances and/or numberof rotations necessary for firing an end effector may depend on theconfiguration of the shaft. Accordingly, the operating system 3904 maybe configured to modify the implement algorithm 3906 received from anend effector based on a corresponding implement algorithm 3906 receivedfrom a shaft.

FIG. 87 is a flowchart showing one example form of a process flow 3400for implementing the control algorithm 3902 utilizing the controlcircuit 3702. At 3402, the control circuit 3702 may execute theoperating system 3904. The operating system 3904 may program the controlcircuit 3702 to take various other actions described herein with respectto the control configuration 3900. At 3404, the control circuit 3702 mayinterrogate one or more implement portions installed with the surgicalinstrument 10, for example, as described herein. At 3406, the controlcircuit 3702 may receive implement algorithms 3906, as described herein.At 3408, the control circuit 3702 may apply the received algorithms 3906to operate the surgical instrument. Applying the received algorithms3906 may include, for example, reconciling the algorithms 3906, asdescribed herein above.

FIGS. 88 and 89 illustrate one form of a surgical instrument 4010comprising a sensing module 4004 located in the end effector 4002. Insome forms, the surgical instrument 4010 may be similar to the surgicalinstrument 10 and the end effector 4002 may be similar to the endeffector 102 described above. The sensing module 4004 may be configuredto measure one or more conditions at the end effector 4002. For example,in one arrangement, the sensing module 4004 may comprise atissue-thickness sensing module that senses the thickness of tissueclamped in the end effector 4002 between the staple cartridge 130 andthe anvil assembly 190. The sensing module 4004 may be configured togenerate a wireless signal indicative of the one or more measuredconditions at the end effector 4002. According to one arrangement shownin FIG. 89, the sensing module 4004 may be located at a distal end ofthe end effector 4002, such that the sensing module 4004 is out of theway of the staples of the staple cartridge 130 when the staples arefired. In various forms, the sensing module 4004 may comprise a sensor,a radio module, and a power source. See FIG. 90. The sensor may bedisposed in the distal end of the end effector 4002 (as shown in FIG.89), at the powered articulation joint 310, or any other suitableportion of the implement portion 100.

In various arrangements, the sensor may comprise any suitable sensor fordetecting one or more conditions at the end effector 4002. For example,and without limitation, a sensor located at the distal end of the endeffector 4002 may comprise a tissue thickness sensor such as a HallEffect Sensor or a reed switch sensor, an optical sensor, amagneto-inductive sensor, a force sensor, a pressure sensor, apiezo-resistive film sensor, an ultrasonic sensor, an eddy currentsensor, an accelerometer, a pulse oximetry sensor, a temperature sensor,a sensor configured to detect an electrical characteristic of a tissuepath (such as capacitance or resistance), or any combination thereof. Asanother example, and without limitation, a sensor located at the poweredarticulation joint 310 may comprise a potentiometer, a capacitive sensor(slide potentiometer), piezo-resistive film sensor, a pressure sensor, apressure sensor, or any other suitable sensor type. In somearrangements, the sensing module 4004 may comprise a plurality ofsensors located in multiple locations in the end effector 4002. Thesensing module 4004 may further comprise one or more visual markers toprovide a visual indication, such as through a video feed, to a user ofthe current condition at the end effector 4002.

The sensing module 4004 may comprise a radio module configured togenerate and transmit a wireless signal indicative of the measuredcondition at the end effector 4002. See FIG. 90. The radio module maycomprise an antenna configured to transmit the wireless signal at afirst frequency. The transmission power of the sensing module 4004 maybe limited by the size of the antenna and the power source locatable inthe sensing module 4004. The size of the end effector 4002 may reducethe available space for placing an antenna or a power source powerfulenough to transmit a signal from the sensing module 4004 to a remotelocation, such as, for example, a video monitor 4014. Due to theconstrained size of the antenna and the low power delivered by the powersource to the sensing module 4004, the sensing module 4004 may produce alow-power signal 4006 capable of transmission over short distances. Forexample, in some forms the sensing module 4004 may transmit a signalfrom the end effector 4002 to the relay station 4008 located proximallyfrom the end effector 4002. For example, the relay station 4008 may belocated at the handle 4020 of the instrument 4010, in the shaft 4030(e.g., a proximal portion of the shaft 4030), and/or in an implantabledevice positioned on or within the patient.

The relay station 4008 may be configured to receive the low-power signal4006 from the sensing module 4004. The low-power signal 4006 is limitedby the size of the antenna and the power source that may be located inthe end effector 4002 as part of the sensing module 4004. The relaystation 4008 may be configured to receive the low-power signal 4006 andretransmit the received signal as a high-power signal 4012. Thehigh-power signal 4012 may be transmitted to remote network or device,such as a video monitor 4014 configured to display a graphicalrepresentation of the measured condition at the end effector 4002.Although the sensing module 4004 and the relay station 4008 havegenerally been described in relation to the surgical instrument 4010,those skilled in the art will recognize that the sensing module 4004 andrelay station 4008 arrangement may be used with any suitable surgicalsystem, such as, for example, a robotic surgical system. For example,the relay station 4008 may be positioned in a shaft and/or instrumentportion of the robotic surgical instrument. A suitable robotic surgicalsystem is described in U.S. patent application Ser. No. 13/538,700,entitled “Surgical Instruments with Articulating Shafts,” which isherein incorporated by reference in its entirety.

In some forms, the video monitor 4014 may comprise a stand-alone unitfor displaying the measured condition at the end effector 4002, astandard viewing monitor for use in endoscopic, laparoscopic, or opensurgery, or any other suitable monitor. The displayed graphicalrepresentation may be displayed overtop of a video feed or otherinformation displayed on the video monitor. In some forms, thehigh-power signal 4012 may interrupt the video monitor 4014 display andmay cause the video monitor to display only the graphical representationof the measured condition at the end effector 4002. A receiver module4015 may be interfaced with the video monitor 4014 to allow the videomonitor 4014 to receive the high-power signal 4012 from the relaystation 4008. In some arrangements, the receiver module 4015 may beformed integrally with the video monitor 4014. The high-power signal4012 may be transmitted wirelessly, through a wired connection, or both.The high-power signal 4012 may be received by a wide-area network (WAN),a local-area network (LAN), or any other suitable network or device.

In some forms, the video monitor 4014 may display images based on datacontained in the received high-power signal 4012. For example, theclinician may see real-time data regarding the thickness of the clampedtissue throughout a procedure involving the surgical instrument 4010.The video monitor 4014 may comprise a monitor, such as a cathode raytube (CRT) monitor, a plasma monitor, a liquid-crystal display (LCD)monitor, or any other suitable visual display monitor. The video monitor4014 may display a graphical representation of the condition at the endeffector 4002 based on the data contained in the received high-powersignal 4012. The video monitor 4014 may display the condition at the endeffector 4002 in any suitable manner, such as, for example, overlaying agraphical representation of the condition at the end effector over avideo feed or other data displayed on the video monitor 4014. In someforms, the video monitor 4014 may be configured to display only datareceived from the high-power signal 4012. Similarly, the high-poweredsignal 4012 may be received by a computer system (not shown). Thecomputer system may comprise a radio-frequency module (such as, forexample, receiver module 4015) for communication with the relay station4008. The computer system may store the data from the high-power signal4012 in a memory unit (e.g., a ROM or hard disk drive) and may processthe data with a processor.

In some forms, the relay station 4008 amplifies the power of thelow-power signal 4006 to a high-power signal 4012 but does not otherwisealter the low-power signal 4006. The relay station 4008 may beconfigured to retransmit the high-power signal 4012 to a remote networkor device. In some arrangements, the relay station 4008 may alter orprocess the received low-power signal 4006 before retransmitting thehigh-power signal 4012. The relay station 4008 may be configured toconvert the received signal from a first frequency transmitted by thesensing module 4004 into a second frequency receivable by a remotenetwork or device, such as the video monitor 4014. For example, in onearrangement, the sensing module 4004 may transmit the low-power signal4006 using a first frequency comprising a human-tissue permeablefrequency. A human-tissue permeable frequency may comprise a frequencyconfigured to pass through human tissue with minimal attenuation of thesignal. For example, a frequency may be chosen outside of a waterabsorption band to limit the attenuation of the signal by human tissue(which may comprise a high percentage of water). For example, thesensing module 4004 may use the Medical Implant Communication Service(MICS) frequency band (402-405 MHz), a suitable industrial, scientific,and medical (ISM) radio band (such as 433 MHz center frequency or 915MHz center frequency), a near field communication band (13.56 MHz), aBluetooth communication band (2.4 GHz), an ultrasonic frequency, or anyother suitable, human-tissue permeable frequency or frequency band. Therelay station 4008 may receive the low-power signal 4006 in the firstfrequency. The relay station 4008 may convert the low-power signal 4006from the first frequency to a second frequency that is suitable fortransmission through air over long ranges. The relay station 4008 mayuse any suitable frequency to transmit the high-power signal 4012, suchas, for example, a Wi-Fi frequency (2.4 GHz or 5 GHz).

In some forms, the relay station 4008 may convert the received low-powersignal 4006 from a first communication protocol to a secondcommunication protocol prior to transmission of the high-power signal4012. For example, the sensing module 4004 may transmit the low-powersignal 4006 using a first communication protocol, such as, for example,a near field communication (NFC) protocol, a Bluetooth communicationprotocol, a proprietary communication protocol, or any other suitablecommunication protocol. The relay station 4008 may receive the low-powersignal 4006 using the first communication protocol. The relay station4008 may comprise a protocol conversion module to convert the receivedsignal from the first communication protocol to a second communicationprotocol, such as, for example, TCP/IP, UDP, or any other suitablecommunication protocol.

FIG. 90 is a block diagram showing a sensing module 4104, whichrepresents an example arrangement of the sensing module 4004 describedherein above. The sensing module 4104 may comprise a sensor 4116, acontroller 4118, a radio module 4124, and a power source 4126. Thecontroller 4118 may comprise a processor unit 4120 and a memory unit4122. The sensor 4116 may be disposed in the distal end of the endeffector 4002 (as shown in FIG. 89), at articulation joint 310, or anyother suitable portion of the implement portion 100. In various forms,the sensor 4116 may comprise any suitable sensor for detecting one ormore conditions at the end effector.

In some arrangements, the sensor 4116 may comprise a tissue thicknesssensor, such as, for example, a Hall Effect sensor. The tissue thicknesssensor may detect the thickness of tissue clamped in the end effector4002 based on a magnetic field generated by a magnet 4042 located, forexample, at a distal end of the anvil assembly 190. See FIG. 89. Whenthe clinician closes the anvil assembly 190, the magnet 4042 rotatesdownwardly closer to the sensing module 4004, thereby varying themagnetic field detected by the sensing module 4004 as the anvil assembly190 rotates into the closed (or clamped) position. The strength of themagnetic field from the magnet 4042 sensed by the sensing module 4004 isindicative of the distance between the channel 130 and the anvilassembly 190, which is indicative of the thickness of the tissue clampedbetween the channel 130 and the anvil assembly 190 when the end effector4002 is in the closed (or clamped) position.

The sensing module 4104 may be configured to generate a wireless signalindicative of the measured condition at the end effector. The wirelesssignal may be generated by the radio module 4124. In some forms, thetransmission power of the radio module 4124 is limited by the size of anantenna included in the radio module 4124 and the size of a power source4126 located in the sensing module 4104. The size of the end effector4002 may reduce the available space for placing an antenna or a powersource 4126 powerful enough to transmit a signal from the sensor 4116 toa remote location, such as, for example, a video monitor 4014. Due tothe limitations on the antenna and the low power delivered by the powersource 4126, the radio module 4124 may only produce a low-power signal4006 capable of transmission over short distances, such as the distanceto the proximal end of the shaft 4030. For example, in one form, theradio module 4124 may transmit the low-power signal 4006 from the endeffector 4002 to the handle 4020 of the surgical instrument 4010. Insome arrangements, a power source 4126 capable of delivering higherpower levels may generate a low-power signal 4006 to prolong operationof the surgical instrument 4010.

The memory unit 4122 of the controller 4118 may comprise one or moresolid state read only memory (ROM) and/or random access memory (RAM)units. In various arrangements, the processor 4120 and the memoryunit(s) 4122 may be integrated into a single integrated circuit (IC), ormultiple ICs. The ROM memory unit(s) may comprise flash memory. The ROMmemory unit(s) may store code instructions to be executed by theprocessor 4120 of the controller 4118. In addition, the ROM memoryunit(s) 4122 may store data indicative of the cartridge type of thecartridge 130. That is, for example, the ROM memory unit(s) 4122 maystore data indicating the model type of the staple cartridge 130. Insome arrangements, a controller in the handle 4020 of the surgicalinstrument 4010 may utilize the condition information and model type ofthe staple cartridge 130 to detect proper operation of the surgicalinstrument 4010. For example, the sensing module 4004 may be configuredto measure tissue thickness. The tissue thickness information and thecartridge model type may be used to determine if the tissue clamped inthe end effector 4002 is too thick or too thin, based on the specifiedtissue thickness range for the particular staple cartridge 130. Theradio module 4124 may be a low power, 2-way radio module thatcommunicates wirelessly, using a wireless data communication protocol,with the relay station 4008 in the handle 4020 of the surgicalinstrument 4010. The radio module 4124 may comprise any suitable antennafor transmission of the low-power signal 4006. For example, the radiomodule 4124 may comprise a dipole antenna, a half-wave dipole antenna, amonopole antenna, a near field communication antenna, or any othersuitable antenna for transmission of the low-power signal 4006. The sizeof the antenna, and therefore the available transmission power andfrequencies, may be limited by the size of the end effector 4002.

According to various forms, the radio module 4124 may communicate withthe relay station 4008 using a human-tissue permeable frequency. Forexample, the communications between the radio module 4124 and the relaystation 4008 may use the Medical Implant Communication Service (MICS)frequency band (402-405 MHz), a suitable industrial, scientific, andmedical (ISM) radio band (such as 433 MHz center frequency or 915 MHzcenter frequency), a Near Field communication band (13.56 MHz), aBluetooth communication band (2.4 GHz), an ultrasonic frequency, or anyother suitable, human-tissue-permeable frequency or frequency band. Thepower source 4126 may comprise a suitable battery cell for powering thecomponents of the sensing module 4004, such as a Lithium-ion battery orsome other suitable battery cell.

In some forms, the components of the sensing module 4104 may be locatedin the end effector 4002, on the shaft 4030, or in any other suitablelocation of the surgical instrument 4010. For example, the sensor 4116may be located in the distal end of the end effector 4002. Thecontroller 4118, the radio module 4124, and the power source 4126 may belocated on the shaft 4030. One or more wires may connect the sensor 4116to the controller 4118, the radio module 4124, and the power source4126. In some forms, the functions of the end effector 4002 and theshaft 4030 may limit the placement of the sensing module 4104. Forexample, in the illustrated form, the end effector 4002 is articulatableand rotatable through the powered articulation joint 310. Placing wiresover the powered articulation joint 310 may result in twisting orcrimping of the wires and may interfere with the operation of thepowered articulation joint 310. The placement of the sensing module 4004components may be limited to a location distal of the poweredarticulation joint 310 to prevent operational issues of the articulationjoint 310 or of the sensing module 4004.

In some arrangements, the sensing module 4104 may comprise an analog todigital convertor (ADC) 4123. The sensor 4116 may generate an analogsignal representative of a condition at the end effector 4002.Transmission of the signal representative of a condition at the endeffector 4002 wirelessly may require conversion of the analog signal toa digital signal. The analog signal produced by the sensor 4116 may beconverted into a digital signal by the ADC 4123 prior to the generationand transmission of the low-power signal 4006. The ADC 4123 may beincluded in the controller 4118 or may comprise a separate controller,such as, for example, a microprocessor, a programmable gate-array, orany other suitable ADC circuit.

FIG. 91 is a block diagram showing a relay station 4208, whichrepresents one example arrangement of the relay station 4008 describedherein above. The relay station 4208 may be located proximal to theshaft, such as, for example, in close proximity with a battery 4226, andspaced away from the sensing module 4004 in the end effector 4002 by,for example, the shaft 4030. For example, the relay station 4208 may belocated in the handle 4020 of the surgical instrument 4010. As such, therelay station 4208 may receive a wireless signal from the sensing module4004. The relay station 4208 may comprise a releasable module that maybe selectively interfaced with the handle 4020 of the surgicalinstrument 4002.

As shown in FIG. 91, the relay station 4208 may comprise a radio module4228 and an amplification module 4230. In some arrangements, the radiomodule 4228 is configured to receive the low-power signal 4006. Thelow-power signal 4006 may be transmitted from the sensing module 4004and is indicative of a condition at the end effector 4002. The radiomodule 4228 of the relay station 4208 receives the low-power signal 4006and provides the low-power signal 4006 to an amplification module 4230.The amplification module 4230 may amplify the low-power signal 4006 to ahigh-power signal 4012 suitable for transmission over a longer rangethan the low-power signal 4006. After amplifying the received low-powersignal 4006 to the high-power signal 4012, the amplification module 4230may provide the high-power signal 4012 to the radio module 4228 fortransmission to a remote network or device, such as, for example, thevideo monitor 4014. The amplification module 4230 may comprise anysuitable amplification circuit, for example, a transistor, anoperational amplifier (op-amp), a fully differential amplifier, or anyother suitable signal amplifier.

FIG. 92 is a block diagram showing a relay station 4308, whichrepresents another example arrangement of the relay station 4008described herein above. In the illustrated form, the relay station 4308comprises a radio module 4328, an amplification module 4330, and aprocessing module 4336. The amplification module 4330 may amplify thereceived low-power signal 4006 prior to processing by the processingmodule 4336, after the processing module 4336 has processed the receivedlow-power signal 4006, or both prior to and after processing by theprocessing module 4336. The radio module 4328 may comprise a receivermodule 4332 and a transmitter module 4334. In some forms, the receivermodule 4332 and the transmitter module 4334 may be combined into asignal transceiver module (not shown). The receiver module 4332 may beconfigured to receive the low-power signal 4006 from the sensing module4004. The receiver module 4332 may provide the received low-power signal4006 to the processing module 4336.

In the illustrated arrangement, the processing module 4336 comprises afrequency conversion module 4338 and a protocol conversion module 4340.The frequency conversion module 4338 may be configured to convert thereceived low-power signal 4006 from a first frequency to a secondfrequency. For example, the sensing module 4004 may transmit thelow-power signal 4006 using a first frequency that is suitable fortransmission through human tissue, such as a MICS or an ISM frequency.The receiver module 4332 may receive the low-power signal 4006 in thefirst frequency. The frequency conversion module 4338 may convert thelow-power signal 4006 from the first frequency to a second frequencythat is suitable for transmission through air over long ranges. Thefrequency conversion module 4338 may convert the received low-powersignal 4006 into any suitable frequency for transmission of thehigh-power signal, such as, for example, a Wi-Fi frequency (2.4 GHz or 5GHz frequencies).

The protocol conversion module 4340 may be configured to convert thereceived signal from a first communication protocol to a secondcommunication protocol. For example, the sensing module 4004 maytransmit the low-power signal 4006 using a first communication protocol,such as, for example, a near field communication (NFC) protocol, aBluetooth communication protocol, a proprietary communication protocol,or any other suitable communication protocol. The relay station 4308 mayreceive the low-power signal 4006 using the first communicationprotocol. The relay station 4308 may comprise a protocol conversionmodule 4340 to convert the received low-power signal 4006 from the firstcommunication protocol to a second communication protocol, such as, forexample, a TCP/IP protocol, a Bluetooth protocol, or any other suitablecommunication protocol. The processing module 4336, including thefrequency conversion module 4338 and the protocol conversion module4340, may comprise one or more microprocessors, programmablegate-arrays, integrated circuits, or any other suitable controller orany combination thereof.

In some forms, the frequency conversion module 4338 and/or the protocolconversion module 4340 may be programmable. Networks, video monitors, orother receiving equipment may be configured to receive signals at aspecific frequency and in a specific protocol. For example, a local-areanetwork (LAN) may be configured to receive a wireless signal using the802.11 wireless standard, requiring a transmission at a frequency of 2.4GHz or 5 GHz and using a TCP/IP communication protocol. A user mayselect the 802.11 wireless communication standard from a plurality ofcommunication standards stored by the relay station 4308. A memorymodule may be included in the relay station 4308 to store the pluralityof communication standards. A user may select a communication standardfor the high-power signal 4012 from the plurality of communicationstandards stored by the memory module. For example, a user may selectthe 802.11 communication standard as the communication standard for thetransmission of the high-power signal 4012. When a communicationstandard is selected by a user, the frequency conversion module 4338 orthe protocol conversion module 4340 may be programmed by the memorymodule to convert the received low-power signal 4006 into the selectedcommunication standard by converting the frequency or communicationprotocol of the received low-power signal 4006. In some arrangements,the relay station 4308 may automatically detect the proper frequency andcommunication protocol for receiving the low-power signal 4006 ortransmitting the high-power signal 4012. For example, the relay station4308 may detect a hospital wireless communication network. The relaystation 4308 may automatically program the frequency conversion module4338 and protocol conversion module 4340 to convert the receivedlow-power signal 4006 into the proper frequency and protocol forcommunication of the high-power signal 4012 to the hospital wirelesscommunication network.

In the illustrated form, the processing module 4336 may provide theprocessed signal to an amplification module 4330 for amplification ofthe processed signal to a high-power signal 4012 prior to transmission.The amplification module 4330 may amplify the processed signal to asuitable level for transmission by a transmission module 4334. Theamplification module 4330 may comprise any suitable amplificationcircuit, for example, a transistor, an operational amplifier (op-amp), afully differential amplifier, or any other suitable electronicamplifier. The amplification module 4330 may comprise a battery (notshown) or may be connected to a power source 4326 located within thehandle 4020 of the surgical instrument 4010. The amplification module4330 may be programmable to provide one or more amplification levels inresponse to the selection of a specific communication type.

The amplification module 4330 may provide the high-power signal 4012 tothe transmission module 4334 for transmission. Although the radio module4328, the processing module 4336, and the amplification module 4330 areshown as separate modules, those skilled in the art will recognize thatany or all of the illustrated modules may be combined into a signalintegrated circuit or multiple integrated circuits.

FIG. 93 illustrates one embodiment of a method for relaying a signalindicative of a condition at an end effector 4400. The method 4400 maycomprise generating 4402, by a sensing module (e.g., the sensing module4004 described herein), a signal indicative of a condition at an endeffector, such as end effector 4002. The signal may represent anymeasurable condition at the end effector 4002, such as, for example, thethickness of tissue clamped in the end effector 4002. The sensing modulemay generate the signal using a sensor, such as, for example, the sensor4116 of the sensing module 4104 shown in FIG. 90. The method 4400 mayfurther comprise, transmitting 4404, by a radio module the generatedsignal as a low-power signal. For example, the radio module 4124 shownin FIG. 90 may transmit a low-power signal 4006. In practice, thetransmission power of the radio module may be limited by the size of theantenna and power source that may be disposed in the end effector 4002.Given the limited space, the transmission power of the radio module maybe limited to a low-power signal 4006. The low-power signal 4006 may betransmitted using the radio module at a power-level that allows thelow-power signal 4006 to be received by a relay station 4008 in thehandle 4020 of the surgical instrument 4010.

The method for relaying the signal indicative of a condition at an endeffector 4400 may further comprise receiving 4406 the low-power signalby a relay station, such as, for example, relay station 4008. Afterreceiving the low-power signal, the relay station may convert 4408 thelow-power signal to a high-power signal, such as, for example, thehigh-power signal 4012. The conversion of low-power signal to high-powersignal may comprise amplification of the low-power signal by anamplification module, such as the amplification module 4230 shown inFIG. 91. Conversion of the low-power signal to high-power signal mayalso comprise converting the communication standard of the low-powersignal to a communication standard suitable for transmission of thehigh-power signal. For example, the method 4400 may comprise converting4408, using a processing module, the received low-power signal from afirst frequency to a second frequency.

After converting 4408 the low-power signal to the high-power signal, themethod 4400 may further comprise transmitting 4410, by the relaystation, the high-power signal to a remote location, such as, forexample, an operating room viewing screen or a hospital network. Thehigh-power signal may be received 4412 by the viewing screen, which maydisplay a graphical representation of the condition at the end effectorto a user. In some arrangements, the method may comprise, selecting, bya user, a frequency and/or a communication protocol for the high-powersignal prior to the conversion of the low-power signal. The frequencyand the communication protocol may be selected from a plurality offrequencies stored in a memory module of the relay station.

Electromechanical Soft Stop

In various forms, the surgical instrument may employ a mechanical stopadapted to stop or decelerate a motor driven element at or near an endof a drive stroke. According to various forms, the mechanical stop maycomprises a hard stop structured to abruptly terminate movement of themotor driven element and/or a soft stop structured to decelerate themotor driven element at or near an end of stroke. As described in moredetail below, in certain forms, such instruments may include anelectromechanical stop comprising the mechanical stop and a controlsystem configured to measure and/or monitor current provided to a motorused to drive the motor driven element. In one form, the control systemis configured to terminate power to the motor or otherwise disengage thedrive motion of the motor driven element upon determining the occurrenceof a current meeting predetermined parameters.

It is to be appreciated that for brevity and ease of understanding thevarious aspects of the mechanical and electromechanical stops describedherein are generally described with respect to surgical instruments andassociated drive members comprising cutting and fastening devices.However, those having skill in the art will appreciate that the presentdisclosure is not so limited and that the various mechanical stops andrelated electromechanical features disclosed herein may find use in avariety of other devices known to the art. For example, while additionaluses will become more apparent below, various mechanical stops disclosedherein may be employed in any device comprising an electricallycontrolled motor and/or control or drive system, for example, as well asnon-endoscopic surgical instruments, such as laparoscopic instruments.Referring again to FIGS. 1-6, which illustrate an electromechanicalsurgical instrument 10 equipped with on form of a mechanical stopaccording to one aspect. The handle assembly 20 is operatively coupledto the elongate shaft assembly 30, a distal portion of which isoperatively attached to the end effector 102. The end effector 102comprises a proximal end 103 and a distal end 104. As described above,the elongate channel member 110 may be configured to operably andremovably support the staple cartridge 130, and the anvil assembly 190may be selectively movable relative to the staple cartridge 130 betweenan open position (see FIG. 4) and an open position (see FIG. 6) tocapture tissue therebetween.

In certain forms, the instrument 10 comprises a drive member, which maybe any portion or component of the instrument 10 that is movable byaction of a motor. In various forms, the drive member may include theelongate shaft assembly 30, the end effector 102, or one or moreportions or components thereof, such as the sled 170 or tissue cuttingmember 160, the body portion 162 of which may be threadably journaled onthe end effector drive screw 180 such that it is rotatably mountedwithin the elongate channel 110. As described above, the sled 170 may besupported for axial travel relative to the end effector drive screw 180and may be configured to interface with the body portion 162 of thetissue cutting member 160. The end effector drive screw 180 may berotatably supported within the elongate channel 110 as described above.Rotation of the end effector drive screw 180 in a first direction causesthe tissue cutting member 160 to move in the distal direction through adrive stroke. As the tissue cutting member 160 is driven distallythrough the drive stroke, the sled 170 is driven distally by the tissuecutting member 160. In various forms, the staple cartridge 130 may befitted with a mechanical stop comprising a soft stop. According to oneaspect, the soft stop comprises one or more bumpers 174 to cushion thesled 170 as it reaches its end of stroke near the distal-most positionwithin the elongate channel 110. The bumpers 174 may each be associatedwith a resistance member 175, such a spring 176, to provide the bumperwith a desired amount of cushion.

As described in greater detail above, the sled 170 and tissue cuttingmember 160 are movable through a drive stoke along shaft axis A-Aextending between the proximal end 103 of the end effector 102 and thedistal end 104 of the end effector 102 to simultaneously cut and fastentissue. While the illustrated end effector 102 is configured to operateas an endocutter for clamping, severing and stapling tissue, in otheraspects, different types of end effectors may be used, such as endeffectors for other types of surgical devices, such as graspers,cutters, staplers, clip appliers, access devices, drug/gene therapydevices, ultrasound, RF or laser devices, etc.

Referring to FIG. 94, which illustrates the distal end 104 of the endeffector 102 shown in FIGS. 1-6, a drive member 158 comprising the sled170 and cutting member 160 is movable through a drive stroke definedalong the shaft axis A-A between a proximal home position and a distalend of stroke position. In one aspect, the end of stroke position isdefined between a first and second position S₁, S₂ (see FIGS. 97 and78). In various forms, at least one of the home position and the end ofstroke includes a mechanical stop, such as a hard stop or soft stop,which may physically impede, e.g., block or limit, additionallongitudinal movement beyond a respective stop position. In one form,both the home position and the end of stroke comprise a mechanical stop.As illustrated, the drive member 158 is distally disposed prior to oradjacent to the end of stroke.

As described above, the surgical instrument 10 may employ a controlsystem for controlling one or more motors and related drive componentsas described above. FIG. 95 is a diagram depicting one form of a systemcomprising a control system 1400, drive motor 1402, and power source1404 for use with a surgical instrument employing an electromechanicalstop, which may include a mechanical soft or hard stop according tovarious aspects. The surgical system comprises a power source 1404operatively coupled to the drive motor 1402 via the control system 1400.The power source 1404 may be configured to supply electric power to thedrive motor 1402 to drive a drive member, such as drive member 158. Incertain aspects, the power source 1404 may comprise any convenientsource of power such as a battery, a/c outlet, generator, or the like.The control system 1400 may comprise various modules or circuits and maybe operative to control various system components, e.g., the drivemember 158, power source 1404, or a user interface. The control system1400 may be configured to control, monitor, or measure variousinstrument 10 operations, signals, inputs, outputs, or parameters, forexample.

In various forms, the control system 1400 may be similar to controlsystem 800 described above. For example, in various aspects, the controlsystem 1400 may be configured to “electrically generate” a plurality ofcontrol motions. The term “electrically generate” refers to the use ofelectrical signals to actuate or otherwise control a motor 1402, forexample motors 402, 530, 560, and 610, or other electrically powereddevice and may be distinguished from control motions that are manuallyor mechanically generated without the use of electrical current. Forexample, the control system 1400 may electrically generate a controlmotion, such as a rotary control motion, comprising delivering power tothe drive motor, which may be in response to a user instruction, such asan electrical signal given to the control system via actuation of anactuator, such a drive or firing trigger associated with the handleassembly 20. In certain aspects, the control system 1400 mayelectrically generate a rotary control motion comprising termination ofpower delivery to the drive motor 1402, which may be in response to auser or biasing mechanism returning the actuator or firing trigger to anopen position. In at least one aspect, the control system 1400 mayelectrically generate a rotary control motion comprising termination orreduction of power delivery to the drive motor 1402 due to a measuredelectrical parameter reaching a predetermined value. For example, thecontrol system 1400 may terminate power delivery to the drive motor 1402when measured current reaches a predetermined threshold.

Referring generally to FIG. 1 and FIGS. 94 and 95, in various forms, thesurgical instrument 10 comprises a handle assembly 20 equipped with auser interface configured to transmit an actuation signal from the user,e.g., a clinician, to the control system 1400 to electrically generate acontrol motion with respect to the elongate shaft assembly 30, the endeffector 102, or the drive member 158. For example, in certain aspects,the user interface comprises a trigger assembly comprising an actuatoror trigger operative to provide an input signal to the control system1400 to control a supply of power to the drive motor 1402, such asfiring motor 530 (see FIG. 23). The assembly may comprise a closuretrigger for closing and/or locking the anvil assembly 190 and a firingtrigger for actuating the end effector 102, e.g., driving the drivemember 158 through the drive stroke. In operation, the closure triggermay be actuated first, thereby bringing the anvil assembly 190 to theclosed position, e.g., capturing tissue between the staple cartridge 130and the anvil assembly 190. Once the clinician is satisfied with thepositioning of the end effector 102, the clinician may draw back theclosure trigger to its fully closed, locked position. The firing triggermay then be actuated from an open position to a closed position toactuate the drive member 158 through the drive stroke. In variousaspects, the firing trigger may return to the open position when theclinician removes pressure or may be mechanically resettable to the openposition via operative connection to the actuation of the drive member158 or a separate mechanism. In one aspect, the firing trigger may be amulti-position trigger whereby once the drive member 158 has reached aposition at or near the end of stroke, the firing trigger may beactuated from a second open position to a second closed position toactuate the drive member 158 proximally toward the home position. Insome such aspects, the first and second open and closed positions may besubstantially the same. Depending on the desired configuration, incertain aspects, a release button or latch may be configured to releasethe closure trigger from the locked position. As explained in moredetail below, following actuation of the firing trigger from the openposition to the closed position, the firing trigger may be operativelydisengaged, e.g., actuation of the firing trigger may provide an initialactuation input signal that may be routed to the control system 1400 toinstruct the control system 1400 to initiate actuation of the drivemember 158. In certain configurations, absent a user override feature,actuation of the drive member 158 will terminate at or near the end ofstroke by action initiated by the control system, e.g., disengaging orinterrupting power delivery to drive motor, even when the firing triggeris in the closed position.

In one form, the trigger assembly comprises a joystick control, whichmay be similar to the joystick control 840 described above. For example,as shown in FIGS. 33-39, the joystick control may beneficially enablethe user to maximize functional control of various aspects of thesurgical instrument 10 through a single interface. In one aspect, thejoystick control rod 842 may be operably attached to the joystick switchassembly 850 that is movably housed within the switch housing assembly844 such that the switch housing assembly 844 is mounted within thepistol grip 26 of the handle assembly 20. The switch housing assembly844 may include a biasing member 856 to bias the joystick switchassembly 850 and the joystick control rod 842 in a desired position whennot subject to external positioning, for example, by a user. Thejoystick control 840 may be electrically coupled to the control system1400 to provide control instructions to the control system 1400. Forexample, manipulation of the joy stick control rod 842, such asdepressing or directional movement, may allow the user may controlvarious control movements associated with the surgical instrument 10,which may include actuation of the drive member 158.

As described above, various forms of the surgical instrument 10 compriseone or more electrically operated or powered motors, such as motors 402,530, 560, and 610. The one or more motors may, for example, be locatedin a portion of the handle assembly 20 or elongate shaft assembly 30 ofthe instrument 10 and be operative to drive the drive member 158 betweenthe home position and the end of stroke. In one form, the motor mayinclude a brushless motor, a cordless motor, a synchronous motor, astepper motor, or any other suitable electric motor. In certainarrangements, the motor may operate in a rotary or linear actuationmode, e.g., a linear actuator, and may include a transmission couplingbetween the drive motor 1402 and drive member 158 to convert rotarymotion of the drive motor 1402 to linear motion or to couple rotarymotion between multiple components. In various forms, a transmissioncoupling comprising one or more gears or interlocking elements such asbelts or pulleys is operative to transmit rotary motion from the drivemotor 1400 to one or more segments of the elongate shaft assembly 30 toactuate the end effector 102. For example, rotation of the end effectordrive screw 180 in a first direction causes the drive member 158 to movein a first direction, e.g., a distal direction, along shaft axis A-A. Invarious aspects, rotation of the end effector drive screw 180 in asecond direction, opposite of the first, causes the drive member 158 tomove in a second direction, e.g., a proximal direction, along shaft axisA-A. In one aspect, the drive motor 1400 drives the drive member 158distally toward the end of stroke and is reversible to drive the drivemember 158 proximally toward the home position. For example, the drivemotor 1402 may be reversible, by, for example, reversing the polarity ofthe voltage supply, thereby producing reverse rotation or motion of themotor and, hence, reverse movement of the drive member 158. As such, thedrive member 158 may be moved between positions along the drive strokein both proximal and distal directions by conventional methods, ormethods such as those disclosed in U.S. patent application Ser. No.12/235,782, which is incorporated herein by reference in its entirety.Notably, although the instruments 10 described herein generally refer tohandheld instruments comprising a handle, in various forms, instruments10 comprising mechanical stops, that may operate as part of anelectromechanical stop, may be adapted for use in robotic or similardevices used by robotic systems.

In certain aspects, the surgical instrument 10 comprises a reversiblemotor and includes a proximal mechanical stop and a distal mechanicalstop. In various aspects, as described above, actuating the firingtrigger signals actuation of the drive member 158 through the drivestroke. When the drive member 158 reaches the end of the drive stroke,for example, when a cutting member 160 reaches the distal end of itscutting stroke, an end of stroke or direction switch, for example, maybe switched to a closed position, reversing the polarity of the voltageapplied to the motor 1402 to thereby reverse the direction of rotationof the motor 1402. Such a switch may be associated with the controlsystem 1400 and may be in addition to or in the alternative totermination of power delivery to the drive motor 1402. Notably, however,in other aspects a manual return switch may be provided to reverse themotor 1402 and return the drive member 158 to its original or homeposition.

A mechanical stop is disposed at or near the end of stroke and isstructured to increase resistance to movement of the drive member 158through the end of stroke. The mechanical stop includes a soft stopcomprising a pair of bumpers 174 each operatively coupled to aresistance member 175. The bumpers 174 are configured to contact thedrive member 158 at or near the end of stroke. For example, the bumpers174 shown in FIG. 94 are structured to contact a contact surface 173 ofat least one wedge 172. In various aspects, the bumpers 174 may bedimensioned to complement a dimension of the contact surface 173. Forexample, in at least on aspect, the bumpers 174 may be dimensioned topresent an angled surface substantially equivalent to the contactsurface 173. In this way, stability of the contact between the bumpers174 and the wedges 172 may be increased and the force applied to thecontact surface 173 may be distributed along a larger structural area ofthe wedges 174. Similarly, in one aspect, the bumpers 174 comprise aflexible, such as an elastic or cushion surface to receive the contactsurface 173 and reduce component breakdown. In one form, the resistancemembers 175 each comprise a spring 176 positioned between a bumper 174and a hard stop 178 to provide resistance and deceleration of the drivemember 158 at or near the end of stroke 158.

It will be appreciated that various aspects of surgical instruments 10may be fitted with multiple bumpers 174 and resistance members 175 andthat bumpers 174 and resistance members 175 may be structured to contactother portions of the drive member 158. For example, the instrument 10may comprise an additional stop, which may be in addition to or insteadof the above hard stop 178 and/or the soft stop arrangements. Thus, inone form, referring to FIG. 94, the drive screw 180 may be fitted with astop that may include a soft stop comprising a bumper 290 associatedwith a resistance member 291 positioned along the drive stroke andopposed to a contact surface 292 of the drive member 158. In one form,the resistance member 291 comprises an elastomeric material that may becompressible between the bumper 292 and a hard stop 294 to absorb thelongitudinal force of the drive member 158. In certain aspects, multiplesoft stops may be configured to contact the drive member 158 atdifferent predetermined positions. For example, in one form, the drivemember 158 contacts bumper 290 before bumpers 174, for example, toprovide a more identifiable current spike, e.g., to produce a currentspike comprising two distinct current spike components, the magnitudeand/or temporal separation of which may be used to increase assurance ofan occurrence of a current spike.

In various forms, resistance members 175 comprise a compressible portionthat may or may not be associated with a hard stop 178. For example, inone aspect a resistance member 175 may be housed between the hard stop178 and the bumper 174 and may include a compressible portion, such as aspring 176, elastomeric material, such as a polymer, foam, or gel. Inoperation, the bumper 174 may be accelerated toward the compressibleportion upon contact with the drive member 158 whereby the compressibleportion compresses by a given degree. In various aspects, the resistancemember 175 may comprise a deceleration portion, such as a brake. In oneaspect the deceleration member comprises a compressible cell, such as ahydraulic pneumatic cell through which contact with the drive member 158may compress a piston positioned within the cell to impart an increasein pressure configured to decelerate or brake the drive member 158. Incertain aspects, the soft stop may be structured to apply a smooth orgradual resistance and/or deceleration with respect to time and/ordistance. For example one or more coiled springs having the same ordifferent compressibility properties may be structured or arranged toprecisely control deceleration or braking of the deceleration member,e.g., in a gradual or stepped manner. In one form, the soft stop may bestructured to apply a progressive resistance to the distal motion of thedrive member 158.

In various forms, a soft stop includes a biasing member configured tobias the contact member away from the hard stop. It will be appreciatedthat, in some aspects, the biasing member may be the same or sharesimilar components with the resistance members 175. Thus, in some forms,a biasing member may be structured to compress between the bumper 174and the hard stop 178 by the longitudinal actuation force of the drivemember 158 and thereafter return to a precompressed state upon removalof the force. In certain aspects, the biasing member may be actuatable,movable, and/or compressible to counter the actuation motion of thedrive member 158. Notably, compressing or otherwise countering a biasassociated with the resistance members 175 may result in an energytransfer that may, at least temporarily, be stored or retained by thesoft stop in a potential energy position. In one aspect, the resistancemembers 175 may be maintained in a potential energy position by a latch,hook, or obstruction, for example, which may prevent one or moreresistance members 175 from returning to a precompressed state.Beneficially, the stored energy may be released, for example, by theuser and/or the control system 1400 whereby at least a portion of thestored energy is applied to return the drive member 158 to the homeposition.

In various aspects, resistance members 175 may comprise additionalconfigurations. For example, in one aspect, one or more magnets, such aspermanent magnets, may be positioned to repel an opposed permanentmagnet associated with the drive member 158. For example, one or moremagnets may be rotatable or movable to adjust the size of repulsivemagnetic fields opposing longitudinal movement. Various other aspectsmay employ coil magnets electrically coupled to the control system foractivation before or after successful deceleration of the drive member158. Additional resistance members 175 may comprise reciprocatingstructures including arrangements implementing pulleys and/or gears, forexample.

In various aspects, a mechanical stop comprising a soft stop may or maynot be associated with a hard stop 178. For example, in some forms thesoft stop includes a hard stop 178, while in other forms the soft stopdoes not include a hard stop or the hard stop 178 may operate as anauxiliary stop. In some forms, the soft stop may comprise a springloaded hard stop 178 to provide a gradual and/or progressive resistanceto the drive stroke or deceleration of the drive member 158. Forexample, the soft stop may be configured to gradually decrease thevelocity of the drive member 158 by providing resistance to the proximalor distal force applied to the drive member 158 by the drive motor 1402or present in the inertia of the system. In at least one form, themagnitude of resistance provided by the soft stop to counter ordecelerate the actuation or drive motion may be selectively adjustable.For example, the instrument 10 may be fitted with one or more soft stopsthat may be selectively slid or rotated to multiple positions along thedrive stroke. As such, a user may customize the position of a soft stopfor a particular application. In one form, an electrochemical devicecomprising a soft stop may include an adjustable dial to adjust theresistance provided by the soft stop along the end of stroke. In somesuch forms, adjusting the dial may simultaneously adjust thelongitudinal distance encompassed by the soft stop and, hence, the endof stoke, as well as threshold values associated with determining acurrent spike, as explained in more detail below. In one form, a warningsignal may be provided to the user when a manual setting is set beyond apredetermined mechanical tolerance.

Referring again to FIG. 95, in various forms, the control system 1400 isconfigured to formulate and/or respond to feedback information that may,at least in part, be derived from information measured by the controlsystem 1400 or obtained from other system components. For example, inone aspect, the control system 1400 may be configured to initiate powerdelivery to system components in response to an input signal, such as aninstruction provided by a user. In certain aspects, the control system1400 may generate or provide information, such as a warning orinstrument state, to a user via the user interface, such as a visual oraudio display. Signals or inputs generated by the control system 1400may be, for example, in response to other signals or inputs provided bya user, instrument components, or may be a function of one or moremeasurements associated with the instrument 10. In certain aspects, thecontrol system 1400 may be configured to monitor or receive variousmeasurements and thereafter interpret, calculate, and/or decode theinformation and respond in a predetermined way.

In one aspect, the control system 1400 includes or may be selectivelyassociated with a semiconductor, computer chip, or memory. As statedabove, inputs provided to or from the control system 1400, such as thosesupplied by the user or produced by the control system 1400 in responseto instructions, signals, or measured parameters may be analog ordigital. Accordingly, in some forms, the control system 1400 may beconfigured to send or receive analog or digital inputs or signals to orfrom instrument components. In various aspects, the control system 1400may use software that may employ one or more algorithms to furtherformulate input signals to control and monitor instrument components.Such formulated input signals may be a function of criteria measuredand/or calculated by the control system 1400 or, in some instances,provided to the control system 1400 by another instrument component, auser, or a separate system in operative communication with the controlsystem 1400. For example, the control system 1400 may respond byactivating or deactivating the drive motor 1402, terminating, initiatingpower to the drive motor 1402 or to additional system components, or byproviding instructions or additional inputs for these or otheroperations. In various aspects, the control system 1400 may comprisecircuitry, for example transistors or switches, configured to monitorelectrical parameters associated with the operation of the instrument10. For example, control system circuitry may be configured to activateor deactivate the drive motor 1402 or open or close a power deliverypath to the drive motor 1402 when electrical parameters associated withoperation of the instrument 10 reach a threshold value, e.g., a currentspike, as determined by the circuitry configuration.

In certain forms, surgical instruments 10 and systems employing amechanical stop may operate in an open loop. For example, in one form,the instruments may operate without assistance from a position feedbackdevice configured to provide the control system 1400 with informationregarding how the instrument 10 is responding to inputs, such that thecontrol system 1400 may modify output. In various aspects, as introducedabove, the control system 1400 may monitor power delivery to a drivemotor 1402 to determine end of stroke position of the drive member 158.That is, for example, the control system 1400 through various voltagemonitory techniques from which current, namely current spikes, may bedetermined, may, at least in part, be ascertained using a mechanicalstop. For example, a control system 1400 may monitor voltage todetermine current with respect to power delivery to a drive motor 1402and, hence, the drive member 158, as described above. Resistance to thedrive stroke increases torque on the drive motor 1402 resulting indetectable current spikes with respect to the power delivered to thedrive motor 1402. Thus, a large current spike may be measured by thecontrol system 1400 when the drive member 158 contacts a mechanical stopat which time the control system 1400 may respond by terminating powerdelivery to the drive motor 1402. Hence, the mechanical stop providesthe physical force to decelerate the drive member 158 and produce thecurrent spike that may be ascertained by the control system 1400 toinitiate disengagement of the drive motor 1400.

As introduced above, in certain aspects, the control system 1400 isconfigured to control various operations of the instrument 10. Forexample, in certain aspects, the control system 1400 comprises a controlcircuit 1406 operatively coupled to a drive circuit 1408. The drivecircuit 1408 may be configured to deliver power from the power source1404 to the drive motor 1402 to drive the drive member 158. The controlcircuit 1406 may be configured to control the delivery of power to thedrive circuit 1408. Hence, the control circuit 1406 may be configured tocontrol the drive motor 1402 via control over power delivery to thedrive circuit 1408. The control circuit 1406 may be further configuredto monitor, e.g., sample or measure, the power delivered to the drivemotor 1402. For example, the control circuit 1406 may sampleinput/output voltage and/or current at one or more points of the drivecircuit 1408 through which the drive motor 1402 receives power toactuate the drive member 158. In various aspects, the control circuit1406 may include or be coupled to the drive circuit 1408 through whichit may monitor input/output voltage, for example across a resistorcoupled to a current path associated with the drive circuit 1408, forexample. As those skilled in the art will appreciate, the abovedescription is just one manner of measuring and/or monitoring currentsupplied to the drive motor 1402 and will further recognize that currentmay similarly be measured and/or monitored by alternate methods known inthe art, and, therefore, such methods are within the scope of thepresent disclosure. In some forms, when the control circuit 1406 detectsa spike in the current supplied to the drive motor 1402, the controlsystem 1400 terminates energy delivery to the drive motor 1402 throughthe drive circuit 1408. In various aspects, the control system 1400 mayalso disengage operative coupling, e.g., transmission, between the drivemotor 1402 and the drive member 158, at least momentarily, in responseto a measured current spike.

In certain configurations, when electromechanical stops comprise a hardstop designed to abruptly terminate the drive stroke, the instrument 10may be susceptible to mechanical failure due to, for example, time lagbetween detection of the current spike and subsequent relief from theactuation force provided by the drive motor 1402. Additionally, due tothe inertia of the system, for example, the drive member 158 may alsocontinue to be actuated or driven after reaching the end of stroke,despite termination of power delivery to the drive motor 1402. In someinstances, the delay in relieving the drive member 158 of the actuationforce may drive the drive member 158, drive motor 1402, drive screw 180,or other transmission coupling to mechanical failure.

FIG. 96 is a graphical illustration depicting current over time of aninstrument 10 employing a electromechanical stop comprising a hard stop178 without a soft stop. The current between time A, corresponding to aposition of the drive member 158 proximal to the end of stroke, and timeB, corresponding to a position of the drive member 158 upon contact withthe hard stop 178 at an end of stroke, is relatively low or steady.However, at time B, the current spikes, representing contact between thedrive member 158 and the hard stop that is positioned at the end ofstroke. Due to a time lag between detection of the current spikesometime after time B and termination of power delivery to the drivemotor 1402, the drive motor 1402 continues to drive the drive member158, although unsuccessfully, against the hard stop 178 until time C,when power delivery to the drive member 158 is terminated. Although notshown, the inertia of the system may also continue to actuate the drivemember 158 against the hard stop 178 for a period of time after time C.

As stated above, while providing the convenience of open loop operation,surgical instruments operating as depicted in FIG. 76 may be susceptibleto mechanical failure due to, for example, the time lag betweendetection of the current spike and subsequent relief from the actuationmotion. According to various forms, referring to FIGS. 97 and 98, theinstruments 10 disclosed herein may comprise electromechanical stopscomprising a soft stop structure to contact and decelerate the drivemember 158 prior to reaching the end of stroke to induce an identifiablecurrent spike, thereby increasing the amount of time the control system1400 has to detect and respond to the current spike. The surgicalinstrument 10 includes various features similar to those illustrated inFIGS. 1 and 70; thus, like features are identified using like numericidentifiers and, for brevity, will not be described again. Theinstrument 10 includes an electromechanical stop comprising a soft stopto oppose movement of a drive member 158 at or near the end of the drivestroke or segment thereof, such as at a proximal home position or adistal end of stroke extending between a first soft stop position S₁ anda second soft stop position S₂ along the shaft axis A-A. Theelectromechanical stop further comprises a hard stop 178 disposed atposition H. The soft stop comprises a bumper 174 and a resistance member175 disposed at or near the end of stroke, e.g., at least partiallywithin the first soft stop position S₁ and second soft stop position S₂.The bumper 174 and resistance member 175 function to provide resistanceto the drive member 158 within the end of stroke defined between thefirst soft stop position S₁ and second soft stop position S₂. In variousforms, the bumper 174 and resistance member 175 may also function todecelerate the drive member 158 from the first soft stop position S₁ tothe second soft stop position S₂. In certain forms, a soft stop may bepositioned in any preferred location where it is desirable to provideresistance to or begin decelerating the drive member 158.

FIG. 97 depicts the drive member 158 in the process of extending throughthe drive stroke at a position proximal to the first soft stop positionS₁. FIG. 98 depicts the drive member 158 after fully extending throughthe drive stroke beyond the first soft stop position S₁ of the end ofstroke such that it is positioned at a second soft stop position S₂ ofthe end of stroke. Accordingly, the soft stop is positioned to contactthe drive member 158 at the first soft stop position S₁ and thereaftercompress distally toward the second soft stop position S₂ due tocompressive interaction with the hard stop at position H. Accordingly,the second soft stop position S₂ may effectively comprise a hard stopposition H* with respect to the drive member and the extreme distalterminus of the end of stroke. In various aspects, the drive member 158may completely or appreciably decelerate prior to reaching the hard stopposition H* at the second soft stop position S₂. Thus, in such aspects,a hard stop, if present, may comprise a redundant or safety feature.

Resistance to the actuation motion provided by the mechanical stop,which may be accompanied by a decelerating or braking force, may begradual, progressive, or stepped with respect to distance and/or time,for example. That is, in some aspects, a soft stop presents a path ofincreased resistance between a first soft stop position S₁ and thesecond soft stop position S₂. Notably, the end of stroke does notnecessarily imply that the functional operation of the drive membercontinues throughout the entire end of stroke, e.g., to the second softstop position S₂. For example, in one form, the end of stroke ispositioned at or slightly proximal to the distal most staple. In anotherform, the position of initial contact with the soft stop, e.g., at thefirst soft stop position S₁, is distal to the distal most staple. Thatis, the drive member 158 may not contact or experience significantresistance to longitudinal movement through the drive stroke until thedistal most staple has been ejected, at which time increased resistanceand/or deceleration may take place. In this way, movement of the drivemember will not be prematurely limited by action of the control system1400.

FIG. 75 is a graphical illustration depicting current over time of aninstrument 10 employing an electromechanical stop comprising a soft stopaccording to various aspects. The current between time A*, correspondingto a position of the drive member 158 proximal to the end of stroke, andtime B*₀, corresponding to a position of the drive member 158 uponcontact with the soft stop, for example at a bumper 174, the current isrelatively low or steady. However, following time B*₀ the currentgradually begins to spike representing increasing resistance to thelongitudinal motion of the drive member. In various aspects, the gradualincrease in resistance may advantageously increase the time in which thecurrent spike occurs, for example between times B*₀ and B*₂, effectivelyslowing down response time to give the control system 1400 time toreact, thus minimizing the adverse effects of the time lag explainedabove with respect to FIG. 96. In certain aspects, the control system1400 may monitor voltage and measure current supplied to the drive motor1402, as described above. The control system 1400 may be configured torespond in a predetermined way to changes in current. For example, uponreaching a threshold current, for example at time B*₁, the controlsystem 1400 may terminate power supply to the drive motor 1402. In oneconfiguration, the threshold current may comprise a time component. Forexample, the threshold current may include a current differential over aspecific period of time. In certain configurations, a current spike maycomprise one of multiple predetermined current thresholds, each definedby a ratio of a current differential over a time period. As can be seenin FIG. 99, the gradual increase in resistance may also advantageouslyreduce impact loading on the end effector 102 upon contact with a hardstop at time B*₂ as well as reduce the time period B*₂ to C* in whichthe drive motor 1402 continues to actuate the drive member 158 againstthe hard stop 178 after distal movement has ceased.

In certain aspects, the control system 1400 may determine that apredetermined current threshold as measured by an increase or slope ofcurrent over time, for example, has been achieved and may thereafterterminate a power input signal provided to drive motor 1402. Forexample, in one configuration, the control system 1400 may monitorcurrent and thereby terminate power delivery to the drive motor 1402when a magnitude of the current increases a predetermined amount over agiven period of time. In various aspects, these or other values, such asthreshold values, may be adjusted by a user such as manually or byaccessing onboard protocol via an administrative link, such a through acomputer. In at least one configuration, the drive circuit 1408 orcontrol circuit 1406 comprises a variable resister such that a user mayvary the current supplied to the drive motor 1402 by varying the extentof actuation with respect to the trigger. For example, the rotation ofthe firing motor 530 may be proportional to the pressure or movement auser applies to the actuator or trigger. In one form the control circuit1406 may communicate with the drive circuit 1408 such that thresholdvalues may be raised or desensitized.

In certain configurations, a plurality of sensors or electricalcomponents may be employed in the end effector 102 to provide variousforms of feedback to the user. In one aspect, sensors may providefeedback to the control system 1400 to automatically control the variousmotors associated with the instrument. For example, in one aspect thesurgical instrument comprises multiple motors, such as motors 402, 530,560, and/or 610, that are actuatable by one or more control systems,such as control systems 800 and 1400, to electrically generate controlmotions. The control systems may be configured to operatively controlthe motors and receive positional feedback from a plurality of sensorsconfigured to monitor positional information. In certain aspects, thecontrol systems may use the positional information to electricalgenerate altered or modulated control motions via control of powerdelivery to one or more motors or may provide various positionalinformation to the user, for example. In various aspects, the controlsystems may be operable in a hybrid open/closed loop system. Forexample, the control system 1400 may be configured to operate the drivemotor 1402, such as firing motor 530 in an open loop as described hereinwhile also operating various other motors, such as shaft rotation motor610, for example, in a closed loop. In one aspect, the control system1400 may be configured such that the user may selectively choose whichmotors the control system 1400 may operate in a closed or open loop to,for example, customize the various operations of the instrument 10 asmay be desired.

It will be appreciated that one or more inputs may be provided by a userwhich may or may not be subject to evaluation by the control system1400. For example, the control system 1400 may include an override modein which one or more inputs provided to the control system 1400 by oneor more users or other control systems in communication with the controlsystem 1400 may be forwarded and/or provided to the instrument 10. Forexample, when the drive member 158 is in the home position, the controlsystem 1400 may lockout, prevent, or ignore instructions to coupledelivery of power to the drive motor 1402 or otherwise engage the drivemotor 1402 to electrically generate the actuation motion of the drivemember 158. In at least one aspect, lockout occurs or is the defaultstate or condition of the system until the occurrence of one or moreevents, such as closure of the anvil 190 or adequate mechanical orelectrical feedback, such as, for example, latching of components, userinitiated override, change in measured parameter at, near, or along thepath or drive member.

In various aspects, one or more mechanical stops including soft stopassemblies according to the present disclosure may be provided in a kit.The kit may have specific application to one or more select devices ormay be universal or modifiable for universal application to a number ofdevices. For example, a soft stop assembly kit may contain a replacementdeceleration member, such as resistance members and/or contact members,such as bumpers. In one form, a kit includes replacement or aftermarketbushings that may be used as or be insertable within a housingdimensioned to support a resistance member in order to increase theresistance provided by the soft stop at one or more locations along thedrive stroke. In various forms, shims may be provided to adjustclearance between a stop and the body of the device. In some aspects,the contact member may include a permanent or temporary, such asreplaceable, modifiable, or upgradeable, contact guard structured to bedisposed between the drive member and the bumper, the resistance member,and/or the hard stop. The contact guard may be formed from an elastic orother material that is at least partially compressible when contacted bythe accelerated mass of the drive member or impacted upon the soft orhard stop. One aspect of a guard may be a polymer that may slip, slide,snap, or be molded onto a portion, such as a contact surface of thedrive member 158. In another aspect, a guard may be fitted or fittableonto a face of the bumper 174. In yet other aspects, the bumper 174 maycomprise a contact configured to contact and at least partially absorbthe force of the accelerated mass of the drive member 158 to prevent orpartially limit the extent of physical damage or mechanical failure tothe drive member 158, drive motor 1402, drive screw 180, or associatedcomponents.

In some forms, removing a surgical instrument, such as the surgicalinstrument 10 shown in FIGS. 1 and 2, from a patient may be difficult,as the end effector 102 may be in an articulated or rotated position,preventing the end effector 102 from passing through a trocar or otheraccess point into a patient. A clinician may be unaware of the currentarticulation state of the end effector 102, such as, for example,articulated along the articulation axis B-B, and may attempt to removethe surgical instrument 10 without first straightening the end effector102. In various forms, a surgical instrument be configured such that itsend effector is straightened based on input from a sensor (e.g., theinstrument may have a sensor-straightened end effector). In this way,the clinician may ensure that end effector 102 is straight with respectto the articulation axis B-B prior to removing the end effector 102 froma patient, such as, for example, through a trocar. In various forms, asensor may be configured to trigger a powered straightening event as theend effector is removed from the patient.

FIG. 105 illustrates one form of a surgical instrument 5810 comprising asensor-straightened end effector 5802. A sensor 5826 a, 5826 b maydetect a gross proximal motion of the surgical instrument 5810. Thegross proximal motion may indicate that the surgical instrument 5810 isbeing removed from the patient, such as through a trocar or an overtube.A minimum threshold proximal motion may be set to prevent the endeffector 5802 from straightening due to a slight proximal adjustment ofthe surgical instrument 5810 during treatment. In various forms, whenthe gross proximal motion of the surgical instrument 5810 exceeds aminimum threshold, the sensor 5826 a, 5826 b may send a signal to amotor, such as, for example, the articulation control motor 402, tocause the motor to straighten the end effector 5802.

In some forms, the sensor 5826 a, 5826 b may be located in the shaft5831, the end effector 5802, the handle 5820, or any other suitablelocation to detect a gross proximal movement of the surgical instrument5810. In various forms, the sensor 5826 a, 5826 b may comprise anysuitable sensor for detecting movement of the surgical instrument 5810.For example, the sensor 5826 a, 5826 b may comprise a sensor configuredto measure acceleration, such as an accelerometer. When theaccelerometer detects acceleration in a proximal direction above apredetermined threshold, the accelerometer may send a signal to thearticulation control motor 402 to activate a straightening process. Asanother example, the sensor 5826 a, 5826 b may comprise a proximitysensor, such as a magnetic sensor, a Hall Effect sensor, a reed switchsensor, or any other suitable proximity sensor. In various forms, theproximity sensor may be configured to measure the proximity of thesensor 5826 a, 5826 b to a fixed point, such as a trocar 5858 or anovertube 5960. As the surgical instrument 5810 is withdrawn in aproximal direction, the proximity between the sensor 5826 a, 5826 b andthe fixed point may decrease, causing the sensor 5826 a, 5826 b to senda signal to the articulation control motor 402 to activate a poweredstraightening process of the end effector 5802. In various forms,multiple sensors may be included to provide a redundant check for thestraightening process.

In one form, a first sensor 5826 a and a second sensor 5826 b may bedisposed on the surgical instrument 5810. The first sensor 5826 a may belocated on a proximal portion of the shaft 5831 and the second sensor5826 b may be located on a distal portion of the shaft 5831. Thoseskilled in the art will recognize that the first and second sensors 5826a, 5826 b may be located in any suitable portion of the surgicalinstrument 5810 such as, for example, the handle 5820, a detachablesurgical module, the shaft 5831, or the sensor-straightened end effector5802. In some forms, the first sensor 5826 a may comprise anaccelerometer configured to detect a gross proximal movement of thesurgical instrument 5810. In some forms, the second sensor 5826 b maycomprise a proximity sensor configured to detect a distance between thesecond sensor 5826 b and a fixed point, such as, for example, the trocar5858. In the illustrated form, the trocar 5858 comprises a plurality ofmagnets 5822. The plurality of magnets 5822 may generate a constantmagnetic field. The second sensor 5826 b may be configured to detect anincrease in intensity of the magnetic field, indicating movement of thesecond sensor 5826 b, and therefore the sensor-straightened end effector5802, towards the trocar 5858.

In one form, the first sensor 5826 a and the second sensor 5826 b may beconfigured to activate a powered straightening process of thesensor-straightened end effector 5802. In operation, the first sensor5826 a may detect a gross proximal movement of the surgical instrument5810 by detecting a proximal acceleration above a predeterminedthreshold. The first sensor 5826 a may send a first signal to thearticulation control motor 402 to activate the powered straighteningprocess. In some forms, the second sensor 5826 b may also detect thegross proximal movement of the end effector by detecting a change in themagnetic field intensity between the sensor 5826 b and a fixed point,such as the trocar 5858. The second sensor 5826 b may send a secondsignal to the articulation control motor 402 to activate the poweredstraightening process.

As shown in FIG. 105, the sensor-straightened end effector 5802 has beenarticulated at the articulation axis B-B (shown in FIG. 1). Thesensor-straightened end effector 5802 may be coupled to a shaft 5831. Anoperator may move the surgical instrument 5810 in a proximal direction,causing the shaft 5831 and the sensor-straightened end effector 5802 tomove in a proximal direction. The proximal movement may be detected by afirst sensor 5826 a. The first sensor 5826 a may comprise anaccelerometer. The first sensor 5826 a may send a signal to anarticulation control motor, such as, for example, the articulationcontrol motor 402 to activate a powered straightening process. Theproximal movement may also be detected by a second sensor 5826 b. Thesecond sensor 5826 b may comprise a magnetic proximity sensor, such as,for example, a Hall Effect sensor or a reed switch sensor. The secondsensor 5826 b may send a signal to the articulation control motor 402 toactivate the powered straightening process. The second sensor 5826 b maysend the signal to the articulation control motor 402 independent of thefirst sensor 5826 a.

As the clinician removes the surgical instrument 5810 from the trocar5858, the powered straightening process straightens thesensor-straightened end effector 5802. After the powered straighteningprocess has completed, the sensor-straightened end effector 5802 is in astraight configuration, as shown in FIG. 106. The straightenedsensor-straightened end effector 5802 may be withdrawn through thetrocar 5858 without damaging the patient or the trocar 5858 and withoutthe clinician needing to manually straighten the sensor-straightened endeffector 5802. In some forms, the surgical instrument 5810 may provide afeedback signal to the user to indicate the activation or progress of apowered straightening process. For example, in some forms, alight-emitting diode (LED) may be located on the handle 5820. The LEDmay be illuminated during the powered straightening process to providethe user with a visual indication that the powered straightening processis occurring.

In some forms, the first and second sensors 5826 a, 5826 b may functionas redundant checks on the straightening process. For example, in someforms, both the first and second sensors 5826 a, 5826 b may provide asignal to the articulation control motor 402 to activate thestraightening process. A signal from either the first sensor 5826 a orthe second sensor 5826 b may cause the articulation control motor 402 tostraighten the sensor-straightened end effector 5802. In some forms, thepowered straightening process may not execute until a signal has beenreceived from both the first sensor 5826 a and the second sensor 5826 b.In some forms, either the first sensor 5826 a or the second sensor 5826b may independently activate the powered straightening process but theprocess may be aborted if a signal is not received from both the firstand second sensors 5826 a, 5826 b within a predetermined time limit. Forexample, the powered straightening process may be initiated by a signalfrom the first sensor 5826 a. If a signal is not received from thesecond sensor 5826 b within a predetermined time limit, the poweredstraightening process may be aborted by the surgical instrument 5810.

In some forms, the surgical instrument 5810 may comprise a stop sensor.The stop sensor may detect contact between the sensor-straightened endeffector 5802 and a tissue section during the straightening process. Ifthe stop sensor detects contact between the sensor-straightened endeffector 5802 and a tissue section, the stop sensor may send a signal tothe articulation control motor 402 to deactivate the straighteningprocess to prevent damage to the patient. In some forms, when the stopsensor determines that the sensor-straightened end effector 5802 is nolonger in contact with a tissue portion, the stop sensor may send asignal to the articulation control motor 402 to continue thestraightening process. In some forms, the stop sensor may send a signalto the operator, for example through a feedback device, to notify theuser that the sensor-straightened end effector 5802 has contacted atissue section and that the straightening process has been deactivated.The stop sensor may comprise, for example, a pressure sensor disposed onthe sensor-straightened end effector 5802.

FIGS. 107 and 108 illustrate one form of a sensor-straightened endeffector 5902. In some forms, the sensor-straightened end effector 5902may be inserted into a patient through an overtube 5960. The overtube5960 may comprise a magnetic ring 5922 located on the distal end of theovertube 5960. A first sensor 5926 a and a second sensor 5926 b may beconfigured to detect movement of the sensor-straightened end effector5902 when the shaft 5931 is withdrawn from the overtube 5960. In someforms, the first sensor 5926 a may comprise an accelerometer and thesecond sensor 5926 b may comprise a magnetic proximity sensor. Thesecond sensor 5926 b may detect a change in a magnetic field strength asthe second sensor 5926 b is moved in a proximal direction towards themagnetic ring 5922. As the second sensor 5926 b approaches the magneticring 5922, the second sensor 5926 b may generate a signal to initiate apowered straightening process of the end effector 5902. The secondsensor 5926 b may comprise any suitable sensor for sensing a changingmagnetic field, such as, for example, a reed switch sensor or a HallEffect sensor. As discussed above, the first sensor 5926 a and thesecond sensor 5926 b may provide a redundant check for the poweredstraightening process. Those skilled in the art will recognize that insome forms, only the first sensor 5926 a or the second sensor 5926 b maybe included. In some forms, additional sensors may be included to detecta gross proximal movement of the surgical instrument 5910.

FIGS. 109 and 110 illustrate one form of a sensor-straightened endeffector 6002 transitioning from an articulated state to a straightenedstate during removal from a trocar 6058. In FIG. 109, thesensor-straightened end effector 6002 is in an articulated position withrespect to the shaft 6031. A clinician may begin to withdraw thesensor-straightened end effector 6002 through the trocar 6058 in aproximal direction, as indicated by arrow ‘A.’ The proximal movement maybe detected by a first sensor 6026 a, a second sensor 6026 b, or boththe first and second sensors 6026 a, 6026 b. The first sensor 6026 a maycomprise an accelerometer configured to detect a gross proximal movementof the shaft 6031. The second sensor 6026 b may comprise a magneticsensor configured to detect a change in a magnetic field between thesecond sensor 6026 b and a fixed point, such as, for example, the trocar6058. The trocar 6058 may comprise a magnet 6022 to generate a magneticfield. As the shaft 6031 is withdrawn through the trocar 6058, thestrength of the magnetic field detected by the magnetic sensor 6026 bwill change proportionally to the distance between the magnetic sensor6026 b and the magnet 6022. The first sensor 6026 a or the second sensor6026 b may generate a signal to the articulation control motor 402 toactivate a powered straightening process to straighten thesensor-straightened end effector 6002 with respect to the shaft 6831.

After the powered straightening process has completed, thesensor-straightened end effector 6002 is in a straight state as shown inFIG. 110. In the straight state, the sensor-straightened end effector6002 may be withdrawn through the trocar 6058 without damaging thepatient, the trocar 6058, and without the clinician needing to manuallystraighten the end effector 6002. In some forms, a clinician may be ableto override the powered straightening process and maintain thesensor-straightened end effector 6002 in an articulated state duringremoval from the trocar 6058.

FIG. 111 illustrates one form of a magnetic ring 6121 that may beattached to a trocar 5858, 6058 or an overtube 5960. The magnetic ring6121 may comprise a plurality of magnets 6122 that may generate amagnetic field. The magnetic field may be detected by a magnetic sensordisposed on a surgical instrument, such as, for example, the secondsensor 6026 b. The magnetic sensor 6026 b may be configured to maintaina sensor-straightened end effector, such as end effector 6002, in astraightened state when the magnetic sensor detects the magnetic fieldgenerated by the magnetic ring 6121. For example, in one form, themagnetic sensor 6026 b may be configured to generate a lockout signalthat prevents articulation of an end effector if the magnetic sensor6026 b detects a magnetic field above a predetermined threshold. Thepredetermined threshold may be determined based on the strength of themagnetic field generated by the magnetic ring 6121 at a specificdistance corresponding to the articulation axis B-B being locatedoutside of the trocar 5858 or the overtube 5960. In some forms, themagnetic sensor 6026 b may activate a powered straightening process whenthe detected magnetic field strength exceeds the predetermined thresholdand may generate a lockout signal to prevent articulation of thesensor-straightened end effector 6002 until the detected magnetic fieldstrength drops below the predetermined threshold.

FIGS. 112 and 113 illustrate one form of a magnetic sensor 6226comprising a reed switch sensor. A reed switch may comprise anelectrical switch 6250 operated by an applied magnetic field. A pair ofcontacts may be disposed on ferrous metal reeds in a hermetically sealedglass envelope. The contacts may be normally open, closing when amagnetic field is present, or normally closed and opening when amagnetic field is applied.

With reference now to FIGS. 105 and 106, a method for controlling asensor straightened end effector is disclosed. Although the method forcontrolling a sensor straightened end effector is described herein withreference to FIGS. 105 and 106, those skilled in the art will recognizethat the method may be used with any of the forms of thesensor-straightened end effector disclosed herein, such as, for example,the forms illustrated in FIGS. 107-113. In one form, the method maycomprise detecting, by a first sensor 5826 a, a gross proximal movementof a surgical instrument 5810. The surgical instrument 5810 may comprisea sensor-straightened end effector 5802. A clinician may articulate thesensor-straightened end effector 5802 during treatment. Once thetreatment is complete, the clinician may begin to withdraw the surgicalinstrument 5810 from the patient, moving the surgical instrument 5810 ina proximal direction. The proximal movement of the surgical instrument5810 may be detected by the first sensor 5826 a. In some forms, thefirst sensor 5826 a may comprise an accelerometer configured to detect agross proximal movement of the surgical instrument 5810. The method mayfurther comprise generating, by the first sensor 5826 a, a signalindicating that a gross proximal movement has been detected. The signalmay be transmitted by the first sensor 5826 a to a controller for thearticulation control motor 402, such as, for example, a control circuitsuch as the control circuit 3702 shown in FIG. 82. Additional motorcontrollers are provided and described with respect to FIGS. 84,114-116, etc. The method may further comprise receiving, by thearticulation control motor 402, the signal from the first sensor 5826 aand activating, by the articulation control motor 402, a poweredstraightening process to straighten the angle of articulation of thesensor-straightened end effector 5802 in response to the receivedsignal. The powered straightening process may return thesensor-straightened end effector 5802 to a zero articulation state.

In some forms, the method may further comprise detecting, by a secondsensor 5826 b, the gross proximal movement of the surgical instrument5810. In some forms, the second sensor 5826 b may comprise a magneticproximity sensor, such as, for example, a Hall Effect sensor or a reedswitch sensor. The second sensor 5826 b may be configured to detect thedistance between the second sensor 5826 b and a fixed point, such as atrocar 5858 or an overtube 5960. The method for controlling asensor-straightened end effector 5802 may further comprise generating,by the second sensor 5826 b, a signal indicating that the gross proximalmovement has been detected. The second signal may be transmitted to thearticulation control motor 402. The method may further comprisereceiving, by the articulation control motor 402, the second signal andactivating, by the articulation control motor 402, the poweredstraightening process to straighten the angle of articulation of thesensor-straightened end effector 5802. In some forms, the second sensor5826 b may generate the second signal independent of the first sensor5826 a.

In some forms, the first and second sensors 5826 a, 5826 b may functionas redundant checks on the straightening process. For example, in someforms, both the first and second sensors 5826 a, 5826 b may provide asignal to the articulation control motor 402 to activate thestraightening process. A signal from either the first sensor 5826 a orthe second sensor 5826 b may cause the articulation control motor 402 tostraighten the sensor-straightened end effector 5802. In some forms, thepowered straightening process may not execute until both a signal hasbeen received from both the first and the second sensors 5826 a, 5826 b.In some forms, either the first sensor 5826 a or the second sensor 5826b may independently activate the powered straightening process but theprocess may be aborted if a signal is not received from both the firstand second sensors 5826 a, 5826 b within a predetermined time limit. Forexample, the powered straightening process may be initiated by a signalfrom the first sensor 5826 a. If a signal is not received from thesecond sensor 5826 b within a predetermined time limit, the poweredstraightening process may be aborted by the surgical instrument 5810.

In one form, various surgical instruments may utilize a modular motorcontrol platform. For example, the modular control platform may beimplemented by the control circuit 3702. FIG. 114 shows one form of amodular motor control platform 6300 comprising a master controller 6306,one or more motor-controller pairs 6309 a-6309 c. The platform 6300 maycontrol one or more motors 6318 a, 6318 b, 6318 c. The motors 6318 a,6318 b, 6318 c may be any motors utilized in a surgical instrument. Forexample, in some forms one or more of the motors 6318 a, 6318 b, 6318 cmay correspond to one or more of the articulation motor 402, the firingmotor 530, the end effector rotation motor 560 and/or the shaft rotationmotor 610.

In various forms, the respective controllers 6306, 6309 a-6309 c may beimplemented utilizing one or more processors (e.g., processorsimplemented on the control circuit 3702). The modular motor controlplatform 6300 may be suitable to control a motor controlled surgicalinstrument, such as, for example, the surgical instrument 10 illustratedin FIGS. 1 and 2. In various forms, the master controller 6306 may bemounted on the distal circuit board 810 or the proximal circuit board820. A first motor controller 6314 a is operatively coupled to a firstmotor 6318 a to provide one or more control signals to the first motor6318 a. A second motor controller 6314 b may be operatively coupled tothe second motor 6318 b and a third motor controller 6314 c may beoperatively coupled to the third motor 6318 c. The motor controllers6314 a-6314 c are in electrical communication with the master controller6306. The master controller 6306 provides control signals to the motorcontrollers 6314 a-6314 c based on a main control process forcontrolling one or more functions of the end effector 6302. The maincontrol process may be a predefined process, a user-defined process, ora device generated process.

In one form, the main control process may define one or more surgicalprocedures performable by the surgical instrument 10 comprising one ormore functions of the shaft 30 and the end effector 102. For example, inone form, the main control process may define a cutting and sealingoperation of the surgical instrument 10. The cutting and sealingoperation may comprise multiple functions of the surgical instrument 10,such as, for example, a clamping function, a stapling function, acutting function, and an unclamping function. A user may indicate theinitiation of a cutting and sealing operation in any suitable manner,such as, for example pressing a button or switch on the handle 20. Thoseskilled in the art will appreciate that any suitable input method may beused to activate one or more functions of the surgical instrument 10.

In one form, when the clinician indicates initiation of the cutting andsealing operation, such as, for example, by pressing a button on thehandle 20, the master controller 6306 may generate a series of controlsignals and provide the control signals to one or more motor controllers6314 a-6314 c. For example, at time to, a cutting and sealing operationmay be initiated. The master controller 6306 may generate a firstcontrol signal indicating that a clamping function should be performed.The first control signal may be transmitted to a first motor controller6314 a coupled to a first motor 6318 a configured to control a clampingmotion of the end effector 6302. The first motor controller 6314 a may,in turn, provide one or more signals to the first motor 6318 a,activating the first motor 6318 a to pivot the anvil assembly 190 of theend effector 102 to clamp tissue located between the anvil assembly 190and the cartridge 130. The master controller 6306 may poll the firstmotor controller 6314 a for a status signal until the first motorcontroller 6314 a indicates the clamping operation has completed. Attime t₁, the first motor controller 6314 a may provide a signal to themaster controller 6306 indicating the clamping function has completed.

At time t₂, a second control signal may be transmitted from the mastercontroller 6306 indicating that a stapling and cutting operating shouldbe performed. The second control signal may be sent to a second motorcontroller 6314 b coupled to a second motor 6318 b. The second motor6318 b may be configured to control proximal and distal movement of thecutting portion 164 and/or the sled 170 disposed within the end effector102. A stapling and cutting operation control signal may result in thesecond motor controller 6314 b activating the second motor 6318 b toadvance the cutting portion 164 and/or the sled 170 in a distaldirection causing the staple cartridge 130 to fire and the cuttingportion 164 to cut tissue clamped by the anvil assembly 190, asdiscussed in more detail above. At time t₃, the cutting portion 164reaches a distal-most point and the second motor controller 6314 b mayprovide a signal to the master controller 6306 indicating that thestapling and cutting operation has completed. The second motorcontroller 6314 b may automatically generate a control signal for thesecond motor 6318 b to reverse the direction of the cutting portion 164until the cutting portion 164 has been fully retracted.

After receiving the signal from the second motor controller 6314 b attime t₃, the master controller 6306 may provide a third control signalto the first motor controller 6314 a indicating that a release functionshould be performed. The first motor controller 6314 a may generate acontrol signal for the first motor 6318 a to cause the first motor 6318a to reverse the earlier clamping operation and to unclamp the anvilassembly 190. The release function may be performed by the first motorcontroller 6314 a and first motor 6318 a simultaneously with thereversing of the second motor 6318 b to retract the cutting portion 164to its starting position. The use of a master controller 6306 andindividual motor controllers 6314 a, 6314 b allows the surgicalinstrument 10 to perform multiple operations simultaneously without overstressing any of the individual controllers 6306, 6314 a, 6314 b.

The motor controllers 6314 a-6314 c may comprise one or more independentprocesses for monitoring and controlling surgical operations, such as,for example, movement of a motor. In some forms, the motor controllers6314 a-6314 c may be configured to operate one or more control feedbackloop mechanisms. For example, in some forms, the motor controllers 6314a-6314 c may be configured as closed loop controllers, such assingle-input-single-output (SISO) or multiple-input-multiple-output(MIMO) controllers. In some forms, the motor controllers 6314 a-6314 cmay operate as proportional-integral-derivative (PID) controllers. A PIDcontroller may operate a control loop using three tuning terms, aproportional gain term, an integral gain term, and a derivative gainterm. A PID controller may comprise a control process configured tomeasure a specified variable and compare the measured value of thespecified variable to an expected value or set-point of the specifiedvariable. The PID controller may adjust a control variable based on thedifference between the measured valued and the expected value of thespecified variable. In some forms, the motor controllers 6314 a-6314 cmay comprise a PID velocity controller. For example, a first motorcontroller 6314 a may measure a specified variable, such as the positionof a motor 6314 a. The first motor controller 6314 a may adjust acontrol variable, such as the speed of the motor 6314 a, based on thedifference between the measured position of the motor 6314 a and aset-point or expected position of the motor 6314 a.

In some forms, the motor controllers 6314 a-6314 c may be configured asfault detection controllers. A fault detection controller may operate afault detection process. In some forms, the fault detection controllermay operate a direct pattern recognition fault process comprisingmonitoring one or more sensors configured to directly indicate a fault,which may be referred to as signal processing based fault detection. Insome forms, a sensor value provided by a sensor is compared to anexpected value of the sensor derived from a model of the surgicalprocess controlled by the fault detection controller, which may bereferred to as model-based fault detection. Those skilled in the artwill recognize that a combination of signal processing and model-basedfault detection may be employed by a motor controller.

In some forms, the motor controllers 6314 a-6314 c may be configured ascurrent/force limiting controllers. A current/force limiting controllermay be configured to limit a measured value, such as the currentdelivered to a motor or the force exerted by a motor, to a predeterminedvalue. For example, in one form, a first motor controller 6314 a may beconfigured to limit the force exerted during a clamping operation to apredetermined value. A force sensor may monitor the force provided by afirst motor 6318 a configured to control a clamping operation of asurgical instrument. When the force value measured by the force sensormatches the predetermined value, the first motor controller 6314 a maycease operation of the first motor 6318 a. In some forms, a motorcontroller 6314 a-6314 c may be configured to monitor the currentdelivered to a motor 6318 a-6318 c. The current drawn by the motor 6318a-6318 c may be indicative of one or more functions of the motor 6318a-6318 c, such as the speed of the motor or the force exerted by themotor during a surgical operation. If the current drawn by the motor6318 a-6318 c exceeds a predetermined threshold, the motor controller6314 a-6314 c may cease operation of the motor to prevent damage to apatient and to the surgical instrument.

In some forms, the motor controllers 6314 a-6314 c may provideindependent verification of the main control process executed by themaster controller 6306. For example, the motor controllers 6314 a-6314 cmay verify that the action requested by the master controller 6306 is avalid action prior to execution of the requested action. In some forms,the motor controller 6314 a-6314 c may use state information to verifythat the requested action is valid. For example, in one form, a firstmotor controller 6314 a may receive an instruction from the mastercontroller 6306 to perform a cutting and stapling operation. The firstmotor controller 6314 a may check the current state of the surgicalinstrument, such as, for example, checking whether the anvil assembly190 is in a clamped position. If the state information matches a validstate for executing a cutting and stapling operation, the first motorcontroller 6314 a may perform the cutting and stapling operation.However, if the state information does not match a valid state forcutting and stapling, the first motor controller 6314 a may indicate afault in the master controller 6306 or the main control process. Thoseskilled in the art will recognize that the motor controllers 6314 a-6314c may comprise one or more control processes and one or more types ofcontrol processes.

FIG. 115 illustrates one form of a modular motor control platform 6400comprising a master controller 6406 and four motor-controller pairs 6409a-6409 d. The modular motor control platform 6400 may also beimplemented by the control circuit 3702 described herein above, forexample, utilizing one or more processors. The modular motor controlplatform 6400 may be configured to control various motors. For example,a distal roll motor 6418 a may operate in a manner similar to thatdescribed herein with respect to the end effector rotation motor 560. Anarticulation motor 6418 b may operate in a manner similar to thatdescribed herein with respect to the articulation motor 402. A proximalroll motor 6418 c may operate in a manner similar to that describedherein with respect to the shaft rotation motor 610. A transaction motor6418 d may operate in a manner similar to that described herein withrespect to the firing motor 530.

The master controller 6406 may be electrically coupled to one or moremotor controllers 6414 a-6414 d. The master controller 6406 may becoupled to the one or more motor controllers 6414 a-6414 d through awired or wireless connection. In some forms, the motors 6418 a-6418 dmay comprise associated motor encoders 6416 a-6416 d configured toprovide a signal indicative of the position of the motor shaft. In someforms, the motor encoders 6416 a-6416 d may be omitted. In one form, themaster controller 6406 may be configured to communicate with any numberof motor controllers 6414 a-6414 d, such as, for example, one to tenmotor controllers. In some forms, the master controller 6406 may beconfigured to communicate with one or more additional peripheralcontrollers (not shown) wherein the peripheral controllers areconfigured to control one or more non-motorized surgical functions, suchas, for example, ultrasonic functions, electrosurgical functions, or anyother suitable function of the surgical instrument.

In one form, the master controller 6406 may synchronously communicatewith the motor controllers 6414 a-6414 d. The communications from themaster controller 6406 may include, for example, providing instructionsto execute a specific sub-routine or function of the motor controller6414 a-6414 d, querying the motor controller 6414 a-6414 d for a statusupdate, and receiving feedback information from the motor controllers6414 a-6414 d. Synchronous communication may be direct communicationbetween the master controller 6406 and the motor controllers 6414 a-6414d where the communications are time synchronized. For example, in theform illustrated in FIG. 114, the master controller 6406 may communicatewith each of the motor controllers 6414 a-6414 d during predefined timewindows. In another form, a token may be passed between the motorcontrollers 6414 a-6414 d to allow the motor controller 6414 a-6414 dcurrently holding the token to communicate with the master controller6406 during a predetermined time period.

In one form, the master controller 6406 may execute a main controlprocess. The main control process may monitor user inputs, executeoperations of the surgical instrument 10, provide feedback to a user, orperform any other functions of the surgical instrument 10. For example,in one form, a master controller 6406 may execute a main control processcomprising a cutting and sealing operation. In some forms, the maincontrol process may provide control signals to each of the motorcontrollers 6414 a-6414 d. Execution of the individual functions of themotors 6418 a-6418 d may be controlled by the motor controllers 6414a-6414 d. In some forms, the master control process may activate ordeactivate one or more of the motors 6418-6418 d based on the attachmentor removal of a module surgical component, such as a modular shaft 30 orimplement portion 100. The master controller 6406 may provide controlsignals to the motor controllers 6414 a-6414 d and may receive statussignals from the motor controllers 6414 a-6414 d. The status signals mayinclude, for example, a function completion signal, a fault signal, anidle signal, or a feedback signal.

In some forms, the function signal may indicate the operation orcompletion status of a function performable by the motor-controllerpairs 6409 a-6409 d. For example, the function signal may indicate thata clamping operation is occurring or has been completed. The functionsignal may also indicate the success of the operation, such as, forexample, indicating the amount of force applied by the tissue clampedduring the clamping operation. A motor controller 6414 a-6414 d maygenerate a fault signal if the motor controller 6414 a-6414 d detects anerror in an associated motor 6418 a-6418 d or in the completion of asurgical operation. The fault signal may cause the master controller6406 to generate a fault signal to the operator, such as, for example, avisual indicator or an audible indicator. The fault signal may alsocause the master controller 6406 to send control signals to the motorcontrollers 6414 a-6414 d to stop any currently executing functions.

An idle signal may be provided by the motor controllers 6414 a-6414 d tothe master controller 6406 to indicate that an associated motor 6418a-6418 d is idle and may be utilized to perform an associated functionof the surgical instrument 10. In one form, an idle signal may indicatethat a function has been performed by a motor 6418 a-6418 d. Forexample, in one form, a first motor controller 6414 a may receive acontrol signal from the master controller 6406 to perform a clampingoperation. The first motor controller 6414 a may convert the controlsignal from the master controller 6406 into one or more control signalsfor the motor 6418 a. Once the motor 6418 a has performed the indicatedfunction, the motor controller 6414 a may transmit an idle signal to themaster controller 6406, indicating that the motor 6418 a has completedthe requested function.

In various forms, a feedback signal may be provided by the motorcontrollers 6414 a-6414 d to the master controller 6406. The mastercontroller 6406 may have one or more associated feedback devices (notshown) to provide feedback to an operator. The feedback signals receivedfrom the motor controllers 6414 a-6414 d may be converted to controlsignals for the feedback devices by the master controller 6406. In someforms, the motor controllers 6414 a-6414 d may provide feedback signalsdirectly to a feedback device.

In some forms, the synchronous communication between the mastercontroller 6406 and the motor controllers 6414 a-6414 d may beinterrupted by an override signal. The override signal may cause themaster controller 6406 to cease synchronous communication and tocommunicate with the motor controller 6414 a generating the overridesignal. In various forms, the override signal may be generated by amotor controller 6414 a as the result of a failure of a motor, an inputsignal from the user, or based on a predetermined threshold in one ormore feedback signals. The override signal may cause the mastercontroller 6406 to send a signal to each of the motor controllers 6414a-6414 d to cease all operation of the motors 6418 a-6418 d until thecondition that caused the generation of the override signal has beenresolved. In one form, the master controller 6406 may generate a signalfor a feedback device to notify the operator of the override signal.

FIG. 116 illustrates one form of a dual-controller modular motor controlplatform 6500. The platform 6500 may also be implemented by the controlcircuit 3702, as described herein. The dual-controller modular motorcontrol platform 6500 comprises a master controller 6506, a slavecontroller 6507, and four motor-controller pairs 6509 a-6509 d. Themodular motor control platform 6400 may be configured to control motors6518 a, 6518 b, 6518 c, 6518 c. For example, a distal roll motor 6518 amay operate in a manner similar to that described herein with respect tothe end effector rotation motor 560. An articulation motor 6518 b mayoperate in a manner similar to that described herein with respect to thearticulation motor 402. A proximal roll motor 6518 c may operate in amanner similar to that described herein with respect to the shaftrotation motor 610. A transaction motor 6518 d may operate in a mannersimilar to that described herein with respect to the firing motor 530.

The modular motor control platform 6400 may be configured to control thearticulation motor 402, the firing motor 530, the end effector rotationor “distal roll” motor 560, and the shaft rotation or “proximal roll”motor 610. The master controller 6506 and the slave controller 6507 mayeach be associated with a subset of the available motor controllers. Forexample, in the illustrated form, the master controller 6506 isassociated with the first and second motor controllers 6526 a-6526 b andthe slave controller 6507 is associated with the third and fourth motorcontrollers 6526 c-6526 d. The master controller 6506 and the slavecontroller 6507 may be in electrical communication. In some forms, theslave controller 6507 may located on the distal circuit board 810 or theproximal circuit board 820. The slave controller 6507 may reduce theload on the master controller 6506 by reducing the number of motorcontrollers 6526 a-6526 d that the master controller 6506 mustcommunicate with and control. The master controller 6506 and the slavecontroller 6507 may receive one or more controller inputs 6508.

In one form, the master controller 6506 may provide control signalsdirectly to a first motor controller 6526 a and a second motorcontroller 6526. The master controller 6506 may also provide controlsignals to the slave controller 6507. The slave controller may providecontrol signals to a third motor controller 6526 c and a fourth motorcontroller 6526 d. By reducing the number of motor controllers 6526a-6526 d that the master controller 6506 must query and control, thedual-controller modular motor control platform 6500 may increaseresponse times or dedicate additional processing load of the mastercontroller 6506 to other tasks. In one form, the master controller 6506may execute a main control process and the slave controller 6507 mayexecute a slave control process to generate one or more signals for themotor controllers 6526 a-6526 d based on input from the mastercontroller 6506. In one form, the slave controller 6507 may receivecontroller inputs from one or more user controls, such as, for example,a clamping button or a firing switch. In one form, the master controller6506 may communicate with one or more slave controllers 6507 and may notprovide any control signals directly to the motor controllers 6526a-6526 d.

In one form, additional slave controllers 6507 may be added to thesystem to control additional motor controllers or surgical modules. Inone form, the slave controller 6507 may only be utilized when apredefined threshold of motor controllers is required. For example, inthe form shown in FIG. 115, four motor controllers 6526 a-6526 d areconnected to the dual-controller modular motor control platform 6500.The master controller 6506 and the slave controller 6507 are eachassociated with two motor controllers 6526 a-6526 d. Deactivation of oneor more motors, such as, for example, by replacing the shaft 30 with adifferent shaft requiring only to motors for articulation, may result indeactivation of the slave controller 6507, as the additional processingpower of the slave controller 6507 is not required to reduce processingload on the master controller 6506. In some forms, deactivation of oneor more motor controllers 6526 a-6526 d may result in the remainingmotor controllers being assigned to an idle slave controller 6507. Forexample, deactivation of the third and fourth motors 6518 c, 6518 dwould result in the slave controller 6507 being idle. The second motorcontroller 6526 b may be disconnected from the master controller 6506and connected to the slave controller 6507 to lessen the processing loadof the master controller 6506. One or more load balancing processes maybe executed as part of the main control process to ensure optimizeddistribution of control between the master controller 6506 and one ormore slave controllers 6507.

Referring now back to FIGS. 114-116, a method for controlling a modularsurgical instrument 10 comprising multiple motor controllers may bedisclosed. Although the method for controlling a modular surgicalinstrument 10 is discussed with respect to FIGS. 114-116, those skilledin the art will recognize that the method may be employed with respectto any embodiment of the surgical instrument, or the various controlplatforms describd herein. The method may comprise generating, by amaster controller 6506, a main control process comprising one or morecontrol signals. The method may further comprise transmitting, from themaster controller 6506 to one or more motor controllers 6526 a-6526 d,the generated control signals. The motor controllers 6526 a-6526 d mayreceive the transmitted control signals. In some forms, the subset ofthe control signals received by a first motor controller 6526 a maycomprise the control signals transmitted by the master controller 6506during a specific time period in which the master controller 6506 andthe first motor controller 6526 a are in synchronous communication. Themethod may further comprise controlling, by the motor controllers 6526a-6526 d, one or more associated motors 6518 a-6518 d based on thecontrol signals received from the master controller 6506.

In some forms, the method may comprise transmitting, by the mastercontroller 6506, one or more control signals to a slave controller 6507.The slave controller 6507 may be in electrical communication with one ormore motor controllers 6526 c-6526 d. The slave controller 6507 mayexecute a slave control process comprising generating one or more motorcontrol signals based on input received from the master controller 6506.The slave control process may further comprise transmitting, by theslave controller 6507, the motor control signals to one or moreelectrically coupled motor controllers 6526 c-6526 d. The method mayfurther comprise controlling, by the motor controllers 6526 c-6526 d,one or more associated motors in response to the received motor controlsignals. In various forms, a subset of the generated motor controlsignals may be synchronously transmitted to each of the motorcontrollers 6526 c-6526 d during a predetermined time period.

FIG. 117 illustrates one form of a main control process 6600 that may beexecuted by a master controller, such as, for example, the mastercontrollers shown in FIGS. 114-116 or any other suitable mastercontroller. In one form, the surgical instrument 10 may comprise fourmotors, such as, for example the articulation motor 402, the firingmotor 530, the end effector rotation or “distal roll” motor 560, and theshaft rotation or “proximal roll” motor 610 and a joystick 842. Thesurgical instrument 10 may be configured to perform a distal rotationfunction, a grasping function, a clamping function, and a firingfunction. The surgical instrument 10 may comprise one or more buttonsfor controlling the various operations of the surgical instrument 10,such as, for example a home button, an unload button, a grasping button,a clamping button, or a fire button. The surgical instrument 10 mayfurther comprise a light-emitting diode (LED) to provide visual feedbackto a user regarding the operation of the surgical instrument 10.

In some forms, when the surgical instrument 10 is activated, the mastercontroller 6406 places the device into a default mode. In theillustrated main control process 6600, the default mode is thearticulation state 6602. The articulation state 6602 may compriseactivation of three of the four available motors. The activated motorsmay control the rotation of the shaft 30 (e.g., the shaft rotation motor610), the end effector 102 (e.g., the end effector rotation motor 560),and/or the articulation of the end effector 102 (e.g., the articulationmotor 410). In the default articulation mode, the joystick 842 may beactive. In the articulation state 6602, the joystick 842 may be used tocontrol the articulation or rotation of the shaft 30 and the endeffector 102. The distal rotation function may be active (or available)while the grasping, clamping, and firing functions are unavailable. Thehome button may also be activated in the default state. The LED may begreen to indicate the surgical instrument 10 is in a state during whichthe surgical instrument 10 may be safely moved.

A user may press the home button 6604 causing the surgical instrument 10to return to a home state 6606, e.g., a starting state in which the endeffector 102 is straightened with respect to the shaft 30 and the shaft30 and end effector 102 are returned to a zero rotation state. The homestate 6606 may be useful for moving from one operation to another or mayallow a user to quickly reorient the surgical instrument 10 duringoperation. Once the home state 6606 has been reached, the master controlprocess 6600 may return 6605 to the default articulation state 6602.

In one form, the end effector 102, illustrated in FIGS. 1 and 2, may bereleasably connected to the shaft 30 to allow different implements to beattached to the shaft 30. The shaft 30 may be releasably connected tothe handle 20 to allow various shafts to be attached to the surgicalinstrument 10. In one form, the master controller 6406 may sense theejection 6608 of an end effector 102 or a shaft 30 from the surgicalinstrument 10 and may disable operation of the surgical instrument 10until a new shaft or implement portion has been attached to the surgicalinstrument 10 and the surgical instrument 10 has been returned to a homestate 6606. After the master control process 6600 has detected a new endeffector 102 and has returned to the home state 6606, the master controlprocess 6600 may enter the default state 6602.

In one form, the surgical instrument 10 may have an end effector 102attached. The end effector 102 may be configured to perform a graspingfunction. The grasping function may comprise grasping an area of tissuebetween the anvil assembly 190 and the cartridge 130 of the end effector102. The surgical instrument 10 may comprise a grasping button toactivate a grasping function. When a user presses 6614 the graspingbutton, the surgical instrument 10 may enter a grasping mode 6616,locking out movement of the end effector 102, such as rotation orarticulation with respect to the shaft 30. The grasping mode 6616 mayactivate a fourth motor (e.g., the firing motor 530) to cause a portionof the end effector 102 to grasp a tissue section, such as, for example,moving the anvil assembly 190 from an open position to a closedposition. A clamping button may be activated when the surgicalinstrument 10 enters a grasping state.

In some forms, a clinician may press 6620 a clamping button, causing thesurgical instrument 10 to enter a clamp mode 6622. In the clamp mode6622, the surgical instrument 10 may lock out the fourth motor toprevent release of the tissue section during a subsequent operation. Theclamp mode 6622 may activate a fire button located on the handle 20.Once the surgical instrument 10 has entered the clamp mode 6622, themaster controller 6406 may change the LED to blue to indicate to theclinician that tissue has been clamped in the anvil assembly 190 andthat the surgical instrument 10 may be fired to cause a stapling andcutting operation.

A clinician may press 6626 a fire button to cause the surgicalinstrument 10 to enter a fire mode 6628. In the fire mode 6628, thesurgical instrument 10 may deactivate the motors configured to controlmovement of the surgical instrument 10, such as, for example, motors1-3. The fire mode 6628 may activate the fourth motor which may beconfigurable to control a stapling and cutting operation as describedabove. The fire button may be held down, causing the master controller6406 to generate control signals for the motor controller associatedwith the fourth motor to activate the stapling and cutting operation,causing a cutting portion 164 and/or a sled 170 to advance within astaple cartridge 130 located in the end effector 102. During the firingsequence, the LED may be set to red by the master controller 6406 toalert the clinician that the surgical instrument 10 is firing. A “firedtag” may be set to true by the master controller 6406, indicating thatthe surgical instrument has been fired and may not be fired again. Themaster controller 6406 or the motor controller associated with thefourth motor may automatically retract the cutting portion 164 when thecutting portion 164 has reached the distal end of the end effector 102.Once the cutting portion 164 has completed the reverse stroke andreturned to its starting position, the master control process 6600 mayreturn 6630 to the clamp state 6622.

A clinician may deactivate 6624 the clamp state 6622 by pressing theclamp button. The master control process 6600 will generate one or morecontrol signals to return to the grasping state 6616 when the clampingstate 6622 is deactivated. The clinician may then release 6618 thegrasping state 6616 and transition into the articulation state 6602, orany other suitable default state. Those skilled in the art willrecognize that the master control process 6600 may be modified toaccommodate any surgical operation or function performable by thesurgical instrument 10 or any attached surgical module. In some forms,the master control process 6600 may be automatically configured based onthe attached shafts, end effectors, or power modules.

In accordance with one general form, there is provided a surgicalinstrument comprising a handle assembly that is configured tosimultaneously and independently electrically generate at least twodiscrete rotary control motions. The surgical instrument may furtherinclude an elongate shaft assembly that operably interfaces with thehandle assembly for independently and simultaneously receiving andtransmitting the at least two discrete rotary control motions to an endeffector operably coupled to the elongate shaft assembly.

In accordance with another general form, there is provided a surgicalinstrument that comprises a handle assembly that is configured tosimultaneously and independently generate at least three discrete rotarycontrol motions. The surgical instrument may further include an elongateshaft assembly that operably interfaces with the handle assembly forindependently and simultaneously receiving and transmitting the at leastthree discrete rotary control motions to an end effector operablycoupled to the elongate shaft assembly.

In accordance with another general form, there is provided a surgicalinstrument that comprises a drive system that is configured toelectrically generate a plurality of discrete rotary control motions.The surgical instrument may further include an elongate shaft assemblythat is operably coupled to the drive system for receiving a firstrotary control motion therefrom for rotating the elongate shaft assemblyabout a shaft axis. The elongate shaft assembly may be configured toreceive and transmit a second rotary control motion from the drivesystem to a surgical end effector that is operably coupled to theelongate shaft assembly to cause the surgical end effector to rotateabout the shaft axis relative to the elongate shaft assembly. Theelongate shaft assembly may be further configured to receive andtransmit a third rotary control motion from the drive system to anarticulation joint that communicates with the elongate shaft assemblyand the surgical end effector to articulate the surgical end effectorabout an articulation axis that is substantially transverse to the shaftaxis.

In accordance with still another general form, there is provided anarticulation joint for a surgical instrument that includes an elongateshaft assembly and a drive system that is configured to generate andapply a plurality of rotary control motions to the elongate shaftassembly. In at least one form, the articulation joint comprises aproximal joint portion that is coupled to the elongate shaft assemblyand a distal joint portion that is movably coupled to the proximal jointportion and is configured to interface with a surgical end effector. Afirst gear train may operably interface with a proximal firing shaftportion of the elongate shaft assembly. A distal firing shaft mayoperably interface with the surgical end effector for transmitting arotary firing motion from the proximal firing shaft to the surgical endeffector while facilitating articulation of the distal joint portionrelative to the proximal joint portion. A second gear train may operablyinterface with a proximal rotation shaft portion of the elongate shaftassembly for transmitting a distal rotational control motion to thesurgical end effector to cause the surgical end effector to rotaterelative to the elongate shaft assembly while facilitating articulationof the distal joint portion relative to the proximal joint portion.

In accordance with another general form, there is provided anarticulation joint for a surgical instrument that has an elongate shaftassembly and a drive system that is configured to generate and apply aplurality of rotary control motions to the elongate shaft assembly. Inat least one form, the articulation joint includes a proximal clevisthat is coupled to the elongate shaft assembly and a distal clevis thatis pivotally pinned to the proximal clevis for selective pivotal travelrelative thereto about an articulation axis that is substantiallytransverse to a shaft axis that is defined by the elongate shaftassembly. A first gear train may be supported in a gear area definedbetween the proximal and distal clevises such that no portion of thefirst gear train extends radially outwardly beyond any portion of thearticulation joint. The first gear train may operably interface with aproximal firing shaft portion of the elongate shaft assembly. A distalfiring shaft may operably interface with the surgical end effector fortransmitting a rotary firing motion from the proximal firing shaft tothe surgical end effector while facilitating pivotal travel of thedistal clevis relative to the proximal clevis. A second gear train maybe supported in the gear area such that no portion of the first geartrain extends radially outwardly beyond any portion of the articulationjoint. The second gear train may operably interface with a proximalrotation shaft portion of the elongate shaft assembly for transmitting adistal rotational control motion to the surgical end effector to causethe surgical end effector to rotate relative to the elongate shaftassembly while facilitating articulation of the distal clevis relativeto the proximal clevis.

In accordance with another general form, there is provided a surgicalinstrument that includes a drive system that is configured to generate aplurality of rotary control motions. An elongate shaft assembly operablyinterfaces with the drive system and may comprise an outer shaft segmentthat operably interfaces with the drive system to receive distalrotational control motions therefrom. An articulation shaft may operablyinterface with the drive system to receive rotary articulation motionstherefrom. The elongate shaft assembly may further include a proximalfiring shaft segment that operably interfaces with the drive system toreceive rotary firing motions therefrom. The surgical instrument mayfurther include an articulation joint that may include a proximal clevisthat is coupled to the elongate shaft assembly and a distal clevis thatis pivotally pinned to the proximal clevis for selective pivotal travelrelative thereto about an articulation axis that is substantiallytransverse to a shaft axis defined by the elongate shaft assembly. Acoupling assembly may rotatably interface with the distal clevis and beconfigured for attachment to a surgical end effector. A distal firingshaft segment may be operably supported by the coupling assembly and beconfigured to interface with a drive shaft portion of the surgical endeffector. A first gear train may operably interface with the proximalfiring shaft segment and the distal firing shaft segment fortransmitting the rotary firing motions from the proximal firing shaftsegment to the distal firing shaft segment while enabling the distalclevis to be selectively pivoted relative to the proximal clevis. Asecond gear train may operably interface with a proximal rotation shaftfor transmitting the distal rotational control motions to the couplingassembly while enabling the distal clevis to be selectively pivotedrelative to the proximal clevis. An articulation drive link mayinterface with the articulation shaft and the distal clevis and beconstrained to move axially relative to the articulation joint inresponse to applications of the rotary articulation motions to thearticulation shaft.

In accordance with yet another general form, there is provided a coverfor an articulation joint that is supported in an elongate shaftassembly of a surgical instrument that is operably coupled to a surgicalend effector that has at least one end effector conductor therein. In atleast one form, the cover comprises a non electrically-conductive hollowbody that has an open distal end and an open proximal end and ajoint-receiving passage that extends therebetween for receiving thearticulation joint therein. The hollow body is configured to permitportions of the articulation joint to be selectively articulatedrelative to each other while substantially enclosing the portions withinthe hollow body. At least one electrically conductive pathway extendsfrom the distal end of the hollow body to the proximal end of the hollowbody. Each of the at least one electrically conductive pathways has adistal end portion that is configured to electrically contact acorresponding end effector conductor when the end effector has beencoupled to the elongate shaft assembly and a proximal end portion thatis configured to electrically contact a corresponding shaft conductor inthe elongate shaft assembly.

In accordance with another general form, there is provided a surgicalinstrument that includes an elongate shaft assembly that has at leastone electrical shaft conductor therein and an articulation joint. In atleast one form, the articulation joint includes a proximal joint portionthat is coupled to the elongate shaft assembly. A distal joint portionis movably coupled to the proximal joint portion for selectivearticulation relative thereto. A coupler assembly is rotatably coupledto the distal joint portion for selective rotation relative thereto. Thecoupler assembly may be configured to be detachably coupled to thesurgical end effector and form an electrically conductive couplerpathway from an end effector conductor in the end effector to thearticulation joint. The surgical instrument may further include anarticulation joint conductor that contacts the conductive couplerpathway and traverses the articulation joint to contact thecorresponding shaft conductor to form an electrically-conductive paththerebetween.

In accordance with another general form, there is provided a surgicalinstrument that includes a control system that contains at least oneelectrical control component. The surgical instrument further includesan elongate shaft assembly that has an a electrical shaft conductor thatoperably communicates with at least one of the electrical controlcomponents. The surgical instrument may further include an articulationjoint that includes a proximal clevis that is coupled to the elongateshaft assembly. A distal clevis is pivotally coupled to the proximalclevis for selective pivotal travel relative thereto. The surgicalinstrument may further include a coupler assembly that is coupled to thedistal clevis and a surgical end effector that is releasably coupled tothe coupler assembly. The surgical end effector may include an endeffector conductor that is arranged for electrical contact with anelectrically conductive coupler pathway formed in the coupler assemblywhen the surgical end effector has been coupled to the coupler assembly.An articulation joint conductor may traverse the articulation joint andbe in electrical contact with the conductive pathway through the couplerassembly and the shaft conductor.

In accordance with yet another general form, there is provided asurgical instrument that includes a handle assembly that has an elongateshaft assembly operably coupled thereto and configured for operablyattachment to a surgical end effector. A motor is supported by thehandle assembly and is configured to apply a rotary motion to one of theelongate shaft or the surgical end effector coupled thereto. Athumbwheel control assembly is operably supported on the handle assemblyand communicates with the motor such that when an actuator portion ofthe thumbwheel control assembly is pivoted in a first direction, themotor applies a rotary motion to one of the elongate shaft assembly andend effector in the first direction and when the actuator portion ispivoted in a second direction, the motor applies the rotary motion toone of the elongate shaft assembly and end effector in the seconddirection.

In accordance with another general form, there is provided a surgicalinstrument that includes a handle assembly that has an elongate shaftassembly rotatably coupled thereto and is configured for operablyattachment to a surgical end effector. A motor is supported by thehandle assembly and is configured to apply a rotary motion to theelongate shaft assembly for selective rotation about a shaft axis. Thesurgical instrument further includes a thumbwheel control assembly thatincludes a thumbwheel actuator member that is pivotally supportedrelative to the handle assembly. A first magnet is supported on thethumbwheel actuator member and a second magnet is supported on thethumbwheel actuator member. A stationary sensor is centrally disposedbetween the first and second magnets when the thumbwheel actuator memberis in an unactuated position. The stationary sensor communicates withthe motor such that when the thumbwheel actuator is pivoted in a firstdirection, the motor applies a rotary motion to the elongate shaftassembly in the first direction and when the thumbwheel actuator memberis pivoted in a second direction, the motor applies the rotary motion tothe elongate shaft assembly in the second direction.

In accordance with another general form, there is provided a surgicalinstrument that includes a handle assembly that has an elongate shaftassembly rotatably coupled thereto and configured for operablyattachment to a surgical end effector such that the end effector may beselectively rotated about a shaft axis relative to the elongate shaftassembly. A motor is supported by the handle assembly and is configuredto apply a rotary motion to the end effector or coupler portion of theelongate shaft assembly to which the end effector is coupled forselective rotation thereof about the shaft axis. The surgical instrumentfurther includes a thumbwheel control assembly that includes athumbwheel actuator member that is pivotally supported relative to thehandle assembly. First and second magnets are supported on thethumbwheel actuator member. A stationary sensor is centrally disposedbetween the first and second magnets when the thumbwheel actuator memberis in an unactuated position. The stationary sensor communicates withthe motor such that when the thumbwheel actuator is pivoted in a firstdirection, the motor applies a rotary motion to the end effector orcoupler position in the first direction and when the thumbwheel actuatormember is pivoted in a second direction, the motor applies the rotarymotion to the end effector or coupler portion in the second direction.

In accordance with yet another general form, there is provided asurgical instrument that includes a housing that supports a plurality ofmotors. The surgical instrument further includes a joystick controlassembly that includes a first switch assembly that is movably supportedby the housing and includes a joystick that is movably mounted theretosuch that pivotal movement of the joystick relative to the first switchassembly causes at least one corresponding control signal to be sent toat least one of the motors communicating therewith. The joystickassembly further includes a second switch assembly that comprises afirst sensor and a second sensor that is movable with the first switchassembly such that movement of the second sensor relative to the firstsensor causes at least one other control signal to be sent to anotherone of the motors communicating therewith.

In accordance with another general form, there is provided a surgicalinstrument that includes a handle assembly that has an elongate shaftassembly rotatably supported relative thereto. A proximal roll motor issupported by the handle assembly and is configured to apply proximalrotary motions to the elongate shaft assembly to cause the elongateshaft assembly to rotate relative to the handle assembly about a shaftaxis. A surgical end effector is operably coupled to the elongate shaftassembly and is configured to perform a surgical procedure uponapplication of at least one firing motion thereto. A firing motor issupported by the handle assembly and is configured to apply firingmotions to a portion of the elongate shaft assembly for transfer to thesurgical end effector. The surgical instrument further includes ajoystick control assembly that comprises a first switch assembly that ismovably supported by the handle assembly and includes a joystick that ismovably mounted thereto such that pivotal movement of the joystickrelative to the first switch assembly causes at least one correspondingcontrol signal to be sent to the proximal roll motor. The joystickcontrol assembly further includes a second switch assembly thatcomprises a first sensor and a second sensor that is movable with thefirst switch assembly such that movement of the second sensor relativeto the first sensor causes at least one other control signal to be sentto the firing motor.

In accordance with another general form, there is provided a surgicalinstrument that includes a handle assembly that has an elongate shaftassembly rotatably supported relative thereto. The surgical instrumentfurther includes an articulation joint that comprises a proximal jointportion that is coupled to the elongate shaft assembly and a distaljoint portion that is movably coupled to the proximal joint portion. Anarticulation motor is supported by the handle assembly and is configuredto apply articulation motions to the articulation joint to cause thedistal joint portion to move relative to the proximal joint portion. Asurgical end effector is operably coupled to the elongate shaft assemblyand is configured to perform a surgical procedure upon application of atleast one firing motion thereto. A firing motor is supported by thehandle assembly and is configured to apply firing motions to a portionof the elongate shaft assembly for transfer to the surgical endeffector. The surgical instrument further includes a joystick controlassembly that comprises a first switch assembly that is movablysupported by the handle assembly and includes a joystick that is movablymounted thereto such that pivotal movement of the joystick relative tothe first switch assembly causes at least one corresponding controlsignal to be sent to the articulation motor. The joystick assemblyfurther includes a second switch assembly that comprises a first sensorand a second sensor that is movable with the first switch assembly suchthat movement of the second sensor relative to the first sensor causesat least one other control signal to be sent to the firing motor.

In accordance with another general form, there is provided a surgicalinstrument for acting on tissue. The instrument comprises at least oneprocessor and operatively associate memory, at least one motor incommunication with the processor and at least one actuation device. Theprocessor is programmed to receive from a removable implement portion afirst variable describing the removable implement. The processor is alsoprogrammed to apply the first variable to an instrument controlalgorithm. Further, the processor is programmed to receive an inputcontrol signal from the actuation device and control the at least onemotor to operate the surgical instrument in conjunction with theremovable implement in accordance with the instrument control algorithmconsidering the input control signal.

In accordance with an additional general form, the processor may beprogrammed to receive from a removable implement an implement controlalgorithm describing operation of the surgical instrument in conjunctionwith the removable implement. The processor may also be programmed toreceive an input control signal from the actuation device and controlthe at least one motor to operate the surgical instrument in conjunctionwith the removable implement in accordance with the implement controlalgorithm considering the input control signal.

In accordance with another general form, a surgical instrumentconfigured to relay a low-power signal from an end effector to a remotedevice may be disclosed. The surgical instrument may comprise a handle,a shaft extending distally from the handle, and an end effector attachedto the distal end of the shaft. A sensor may be disposed in the endeffector. The sensor may generate a signal indicative of a condition atthe end effector. A transmitter may be located in the end effector. Thetransmitter may transmit the signal from the sensor at a first powerlevel. The signal may be received by a relay station located in thehandle of the surgical instrument. The relay station is configured toamplify and retransmit the signal at a second power level, wherein thesecond power level is higher than the first power level.

In accordance with an additional general form, a relay station forrelaying a signal from an end effector of a surgical instrument to aremote device may be disclosed. The relay station comprises a receiverconfigured to receive a signal from a sensor disposed in an endeffector. The signal is transmitted at a first power level. The relaystation further comprises an amplifier configured to amplify the signalto a second power level. A transmitter is configured to transmit thesignal at the second power level. The second power level is higher thanthe first power level.

In accordance with a general form, a method for relaying a signalreceived from a sensing module in an end effector may be disclosed. Themethod comprises generating, by a sensor, a first signal indicative of acondition at a surgical end effector. The sensor is located in the endeffector. The method further comprises transmitting, using atransmitter, the first signal at a first power level and receiving thetransmitted signal, using a receiver, at a relay station. The firstsignal is amplified by the relay station using an amplifier to ahigh-power signal comprising a second power level. The second powerlevel is greater than the first power level. The high-power signal istransmitted, using the relay station, at the second power level. Thehigh-power signal is received by a remote device, such as a videomonitor. The video monitor displays a graphical representation of thecondition at the surgical end effector.

Some portions of the above are presented in terms of methods andsymbolic representations of operations on data bits within a computermemory. These descriptions and representations are the means used bythose skilled in the art to most effectively convey the substance oftheir work to others skilled in the art. A method is here, andgenerally, conceived to be a self-consistent sequence of actions(instructions) leading to a desired result. The actions are thoserequiring physical manipulations of physical quantities. Usually, thoughnot necessarily, these quantities take the form of electrical, magneticor optical signals capable of being stored, transferred, combined,compared and otherwise manipulated. It is convenient, at times,principally for reasons of common usage, to refer to these signals asbits, values, elements, symbols, characters, terms, numbers, or thelike. Furthermore, it is also convenient, at times, to refer to certainarrangements of actions requiring physical manipulations of physicalquantities as modules or code devices, without loss of generality.

Certain aspects of the present invention include process steps andinstructions described herein in the form of a method. It should benoted that the process steps and instructions of the present inventioncan be embodied in software, firmware or hardware, and when embodied insoftware, can be downloaded to reside on and be operated from differentplatforms used by a variety of operating systems.

The present invention also relates to an apparatus for performing theoperations herein. This apparatus may be specially constructed for therequired purposes, or it may comprise a general-purpose computerselectively activated or reconfigured by a computer program stored inthe computer. Such a computer program may be stored in a computerreadable storage medium, such as, but not limited to, any type of diskincluding floppy disks, optical disks, CD-ROMs, magnetic-optical disks,read-only memories (ROMs), random access memories (RAMs), EPROMs,EEPROMs, magnetic or optical cards, application specific integratedcircuits (ASICs), or any type of media suitable for storing electronicinstructions, and each coupled to a computer system bus. Furthermore,the computers and computer systems referred to in the specification mayinclude a single processor or may be architectures employing multipleprocessor designs for increased computing capability.

The methods and displays presented herein are not inherently related toany particular computer or other apparatus. Various general-purposesystems may also be used with programs in accordance with the teachingsherein, or it may prove convenient to construct more specializedapparatus to perform the required method actions. The required structurefor a variety of these systems will appear from the above description.In addition, the present invention is not described with reference toany particular programming language. It will be appreciated that avariety of programming languages may be used to implement the teachingsof the present invention as described herein, and any references aboveto specific languages are provided for disclosure of enablement and bestmode of the present invention.

In various forms, a surgical instrument configured to relay a low-powersignal from an end effector to a remote device is disclosed. Thesurgical instrument may comprise a handle, a shaft extending distallyfrom the handle, and an end effector attached to the distal end of theshaft. A sensor may be disposed in the end effector. The sensor maygenerate a signal indicative of a condition at the end effector. Atransmitter may be located in the end effector. The transmitter maytransmit the signal from the sensor at a first power level. The signalmay be received by a relay station located in the handle of the surgicalinstrument. The relay station is configured to amplify and retransmitthe signal at a second power level, wherein the second power level ishigher than the first power level.

In various forms, a relay station for relaying a signal from an endeffector of a surgical instrument to a remote device is disclosed. Therelay station comprises a receiver configured to receive a signal from asensor disposed in an end effector. The signal is transmitted at a firstpower level. The relay station further comprises an amplifier configuredto amplify the signal to a second power level. A transmitter isconfigured to transmit the signal at the second power level. The secondpower level is higher than the first power level.

In various forms, a method for relaying a signal received from a sensingmodule in an end effector is disclosed. The method comprises generating,by a sensor, a first signal indicative of a condition at a surgical endeffector. The sensor is located in the end effector. The method furthercomprises transmitting, using a transmitter, the first signal at a firstpower level and receiving the transmitted signal, using a receiver, at arelay station. The first signal is amplified by the relay station usingan amplifier to a high-power signal comprising a second power level. Thesecond power level is greater than the first power level. The high-powersignal is transmitted, using the relay station, at the second powerlevel. The high-power signal is received by a remote device, such as avideo monitor. The video monitor displays a graphical representation ofthe condition at the surgical end effector.

In various forms, a sensor-straightened end effector is disclosed. Thesensor-straightened end effector may comprise an end effector coupled toa shaft at an articulation point. The end effector may be articulable atan angle with respect to the shaft. A sensor may be disposed on thesensor-straightened end effector, such as on the shaft or on the endeffector. The sensor is configured to detect a gross proximal movementof the surgical instrument. When detecting a gross proximal movement,the sensor may generate a signal to control a motor to straighten theend effector with respect to the shaft.

In various forms, a surgical instrument comprising a sensor-straightenedend effector is disclosed. The surgical instrument may comprise ahandle. A shaft may extend distally from the handle. A motor may bedisposed within the handle for controlling an articulation of thesurgical instrument. An articulating end effector is disposed at thedistal end of the shaft. A sensor may be disposed in the handle, theshaft, or the end effector. The sensor may be configured to detect agross proximal movement of the surgical instrument. When the sensordetects the gross proximal movement, the sensor may activate a poweredstraightening process, causing the motor to straighten the articulatedend effector. In some forms, multiple sensors may provide redundantchecks for the straightening process.

In various forms, a method for operating a surgical instrumentcomprising a sensor straightened end effector is disclosed. The methodmay comprise detecting, by a first sensor, a proximal movement of thesurgical instrument. The first sensor may be located in any suitablesection of the surgical instrument, such as the handle, shaft, or endeffector. The first sensor may be an accelerometer, a magnetic sensor,or any other suitable sensor type. The sensor may generate a signalindicating that a gross proximal movement has been detected. The methodmay further comprise receiving, by a motor, the generated signal fromthe first sensor. The motor may straighten an angle of articulation ofthe motor-controlled articulating end effector in response to thereceived signal. A second sensor may generate a second signal to providea redundant check.

In various forms, the present disclosure is directed towards amotor-driven surgical instrument comprising a modular motor controlplatform. A master controller may execute a main control process forcontrolling one or more operations of the surgical instrument. A firstmotor controller and a second motor controller may be operativelycoupled to the master controller. The first motor controller may have anassociated first motor and the second motor controller may have anassociated second motor. The main control process may generate controlsignals for the first and second motor controllers. The first and secondmotor controllers may operate the first and second motors in response tothe control signals. In some forms, the modular motor control system maycomprise a slave controller configured to control one or more of themotor controllers based on one or more control signals received by theslave controller from the master controller.

In various forms, a modular motor control system may comprise one ormore motor controllers each having an associated motor. The one or moremotor controllers may be in communication with a master controller. Themaster controller may be configured to provide control signals to themotor controllers as part of a main control process. The motorcontrollers may control the associated motors in response to thereceived control signals. In some forms, the one or more motorcontrollers and the associated motors may be located within a handleadapted to receive a modular shaft, a modular end effector, and amodular power supply. The handle may provide an interface between themotors and the modular shaft and end effector.

In various forms, a surgical instrument may include a modular motorcontrol system. The surgical instrument may comprise a mastercontroller. The surgical instrument may be configured to receive modularsurgical components, such as a modular shaft and implement portion. Thesurgical instrument may have one or more motors and associated motorcontrollers mounted therein. The motor controllers may be operativelycoupled to the motors. The motors may be configured to control one ormore movements of an attached shaft or implement portion. The mastercontroller and the motor controllers may be in electrical communication.The master controller may be configured to provide one or more controlsignals to the motor controllers as part of the main control process.The motor controllers may control the motors in response to the receivedcontrol signals.

In various forms, a method for controlling a motor-driven surgicalinstrument is disclosed. The method may comprise generating, by a mastercontroller, one or more control signals. A first control signal may betransmitted to a first motor controller configured to control a firstmotor. The first motor controller may operate the first motor inresponse to the first control signal received from the mastercontroller. A second control signal may be transmitted to a second motorcontroller configured to a control a second motor. The second motorcontroller may operate the second motor in response to the secondcontrol signal received from the master controller. In some forms, thesecond control signal may be generated by a slave controller.

In accordance with one general form, there is provided a surgicalinstrument comprising a drive motor and a drive member that is movableby the drive motor through a drive stroke between a home position and anend of stroke position. The end of stroke position extends between afirst position and a second position. A mechanical stop may be disposedat or near the end of stroke position and may be structured to increaseresistance to the movement of the drive member through the drive strokefrom the first position to the second position. The mechanical stop maycomprise a bumper and a resistance member. The bumper may be movablefrom the first position to the second position and be configured tocontact the drive member at the first position. The resistance membermay be operatively coupled to the bumper and configured to increaseresistance to movement of the drive member from the first position tothe second position. The resistance member may be configured todecelerate the drive member prior to the drive member actuating to thesecond position. In one form, the resistance member is structured to becompressible to progressively increase the resistance to the movement ofthe drive member between the first position and the second position. Theresistance member may in one form comprise a spring. The bumpers maycomprise contact surfaces that are dimensioned to complement a dimensionof a drive member surface contacted at the first position.

In one form, a control system is configured to detect a current spikeassociated with the increased resistance to the movement of the drivemember. The control system may monitor voltage associated with thedelivery of power to the drive motor to detect the current spike. Thecurrent spike may comprise a predetermined threshold current. Thepredetermined threshold current may comprise at least one predeterminedthreshold current differential over at least one defined time period.When the control system detects the current spike, delivery of power tothe drive motor may be interrupted. In one form, the mechanical stop mayfurther comprise a hard stop that may prevent movement of the drivemember beyond the second position.

In accordance with one general form, there is provided a mechanical stopfor use in a surgical instrument to produce a detectable current spikeassociated with an electromechanical stop. For example, the mechanicalstop may be disposed at or near an end of stroke associated with a drivestroke of a drive member. The end of stroke may extend between a firstposition and a second position. The mechanical stop may comprise one ormore bumpers and one or more resistance members. The bumpers may bemovable from the first position to the second position and may beconfigured to contact the drive member at the first position. Theresistance members may be operatively coupled to the bumpers andconfigured to increase resistance to movement of the drive member fromthe first position to the second position to produce the current spike.The resistance members may be configured to decelerate the drive memberprior to the drive member actuating to the second position. One or moreof the resistance members may be structured to be compressible toprogressively increase the resistance to the movement of the drivemember between the first position and the second position. One or moreresistance members may also be structured to be compressible and maycomprise at least one spring. The bumpers may comprise contact surfacesthat are dimensioned to complement a dimension of a drive member surfacethat is contacted at the first position. The current spike associatedwith the increased resistance may be detectable by a control systemassociated with the electromechanical surgical instrument. The controlsystem may be configured to monitor voltage associated with powerdelivery to a drive motor and to interrupt the delivery of power to thedrive motor when the current spike comprises at least one predeterminedthreshold current. At least one threshold current may comprise a currentdifferential over at least one defined time period. In one form, themechanical stop further comprises a hard stop for preventing movement ofthe drive member beyond the second position.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, the device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, the devicecan be disassembled, and any number of the particular pieces or parts ofthe device can be selectively replaced or removed in any combination.Upon cleaning and/or replacement of particular parts, the device can bereassembled for subsequent use either at a reconditioning facility, orby a surgical team immediately prior to a surgical procedure. Thoseskilled in the art will appreciate that reconditioning of a device canutilize a variety of techniques for disassembly, cleaning/replacement,and reassembly. Use of such techniques, and the resulting reconditioneddevice, are all within the scope of the present application.

Preferably, the invention described herein will be processed beforesurgery. First, a new or used instrument is obtained and if necessarycleaned. The instrument can then be sterilized. In one sterilizationtechnique, the instrument is placed in a closed and sealed container,such as a plastic or TYVEK bag. The container and instrument are thenplaced in a field of radiation that can penetrate the container, such asgamma radiation, x-rays, or high-energy electrons. The radiation killsbacteria on the instrument and in the container. The sterilizedinstrument can then be stored in the sterile container. The sealedcontainer keeps the instrument sterile until it is opened in the medicalfacility.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdoes not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractice in the art to which this invention pertains.

What is claimed is:
 1. An articulation joint for a surgical instrumentthat includes an elongate shaft assembly and a drive system that isconfigured to generate and apply a plurality of rotary control motionsto the elongate shaft assembly, the articulation joint comprising: aproximal joint portion coupled to the elongate shaft assembly; a distaljoint portion movably coupled to the proximal joint portion andconfigured to interface with a surgical end effector, a first gear trainoperably interfacing with a proximal firing shaft portion of theelongate shaft assembly and a distal firing shaft operably interfacingwith the surgical end effector for transmitting a rotary firing motionfrom the proximal firing shaft to the surgical end effector whilefacilitating articulation of the distal joint portion relative to theproximal joint portion; and a second gear train operably interfacingwith a proximal rotation shaft portion of the elongate shaft assemblyfor transmitting a distal rotational control motion to the surgical endeffector to cause the surgical end effector to rotate relative to theelongate shaft assembly while facilitating articulation of the distaljoint portion relative to the proximal joint portion.
 2. Thearticulation joint of claim 1 wherein the first gear train is nestedwithin the second gear train.
 3. The articulation joint of claim 1wherein the distal joint portion is configured to interface with anarticulation shaft portion of the elongate shaft assembly to receivearticulation motions therefrom.
 4. The articulation joint of claim 4wherein the distal joint portion is configured to pivot relative to theproximal joint portion upon application of rotary articulation motionsto the articulation shaft portion of the elongate shaft assembly.
 5. Thearticulation joint of claim 4 wherein the articulation joint furthercomprises an articulation drive link operably coupled to the distaljoint portion, the articulation drive link interfacing with thearticulation shaft and being constrained to move axially relative to thearticulation joint in response to the application of the rotaryarticulation motions to the articulation shaft.
 6. The articulationjoint of claim 5 wherein the articulation drive link threadably engagesthe articulation shaft.
 7. The articulation joint of claim 1 wherein thedistal joint portion rotatably interfaces with a coupler assembly thatis configured to be removably coupled to the surgical end effector. 8.The articulation joint of claim 7 wherein a portion of the second geartrain interfaces with the coupler assembly to cause the coupler assemblyto rotate relative to the distal joint portion upon the application ofthe distal rotational control motion to the proximal rotation shaftportion of the elongate shaft assembly.
 9. The articulation joint claim7 further comprising locking assembly on the coupler assembly forreleasably locking the surgical end effector to the coupler assembly.10. The articulation joint of claim 1 wherein the distal firing shaftsegment is configured to transfer the rotary firing motion to an endeffector drive screw that is operably supported in the surgical endeffector while facilitating the rotation of the surgical end effectorrelative to the articulation joint.
 11. An articulation joint for asurgical instrument including an elongate shaft assembly and a drivesystem configured to generate and apply a plurality of rotary controlmotions to the elongate shaft assembly, the articulation jointcomprising: a proximal clevis coupled to the elongate shaft assembly; adistal clevis pivotally pinned to the proximal clevis for selectivepivotal travel relative thereto about an articulation axis that issubstantially transverse to a shaft axis defined by the elongate shaftassembly; a first gear train supported in a gear area defined betweenthe proximal and distal clevises such that no portion of the first geartrain extends radially outwardly beyond any portion of the articulationjoint, the first gear train operably interfacing with a proximal firingshaft portion of the elongate shaft assembly and a distal firing shaftoperably interfacing with the surgical end effector for transmitting arotary firing motion from the proximal firing shaft to the surgical endeffector while facilitating pivotal travel of the distal clevis relativeto the proximal clevis; and a second gear train supported in the geararea such that no portion of the first gear train extends radiallyoutwardly beyond any portion of the articulation joint, the second geartrain operably interfacing with a proximal rotation shaft portion of theelongate shaft assembly for transmitting a distal rotational controlmotion to the surgical end effector to cause the surgical end effectorto rotate relative to the elongate shaft assembly while facilitatingarticulation of the distal clevis relative to the proximal clevis. 12.The articulation joint of claim 11 wherein the first gear train isnested within the second gear train such that no portion of the firstgear train extends radially beyond a portion of the second gear train.13. The articulation joint of claim 11 wherein the first gear traincomprises: a proximal drive shaft bevel gear attached to the proximalfiring shaft portion; a drive shaft transfer gear in meshing engagementwith the proximal drive shaft bevel gear; and a distal drive shaft bevelgear in meshing engagement with the drive shaft transfer gear andcoupled to the distal firing shaft and wherein the second gear traincomprises: an input bevel gear coupled to the proximal rotation shaftportion; a rotation shaft transfer gear in meshing engagement with theinput bevel gear; and an out put bevel gear in meshing engagement withthe rotation shaft transfer gear and coupled to a coupler assemblyrotatably interfacing with the distal clevis portion and being couplableto the surgical end effector.
 14. The articulation joint of claim 11wherein the distal clevis is configured to interface with anarticulation shaft portion of the elongate shaft assembly to receivearticulation motions therefrom.
 15. The articulation joint of claim 14further comprising: an articulation drive link interfacing with thearticulation shaft and being constrained to move axially relative to thearticulation joint in response to an application of rotary articulationmotions to the articulation shaft; and an articulation bar coupled tothe distal clevis and the articulation drive link and extendingtherebetween.
 16. The articulation joint of claim 11 wherein the distaldrive shaft is operably supported in a coupling assembly rotatablyinterfacing with the distal clevis, the distal drive shaft configured toreleasably engage an end effector drive screw in the surgical endeffector when the surgical end effector is coupled to the couplingassembly.
 17. A surgical instrument comprising: a drive systemconfigured to generate a plurality of rotary control motions; anelongate shaft assembly operable interfacing with the drive system, theelongate shaft assembly comprising: an outer shaft segment operablyinterfacing with the drive system to receive distal rotational controlmotions therefrom; an articulation shaft operably interfacing with thedrive system to receive rotary articulation motions therefrom; and aproximal firing shaft segment operably interfacing with the drive systemto receive rotary firing motions therefrom and wherein the surgicalinstrument further comprises: an articulation joint further comprising:a proximal clevis coupled to the elongate shaft assembly; a distalclevis pivotally pinned to the proximal clevis for selective pivotaltravel relative thereto about an articulation axis that is substantiallytransverse to a shaft axis defined by the elongate shaft assembly; acoupling assembly rotatably interfacing with the distal clevis andconfigured for attachment to a surgical end effector; a distal firingshaft segment operably supported by the coupling assembly and configuredto interface with a drive shaft portion of the surgical end effector; afirst gear train operably interfacing with the proximal firing shaftsegment and the distal firing shaft segment for transmitting the rotaryfiring motions from the proximal firing shaft segment to the distalfiring shaft segment while enabling the distal clevis to be selectivelypivoted relative to the proximal clevis; a second gear train operablyinterfacing with a proximal rotation shaft for transmitting the distalrotational control motions to the coupling assembly while enabling thedistal clevis to be selectively pivoted relative to the proximal clevis;and an articulation drive link interfacing with the articulation shaftand the distal clevis and being constrained to move axially relative tothe articulation joint in response to applications of the rotaryarticulation motions to the articulation shaft.
 18. The surgicalinstrument of claim 17 wherein the first gear train is nested within thesecond gear train.
 19. The surgical instrument of claim 17 wherein thedrive system is operably supported in a handle assembly operably coupledto the elongate shaft assembly.
 20. The surgical instrument of claim 17wherein the drive system comprises a portion of a robotic system.